Ford - Crown Victoria - Workshop Manual - 1996 - 1996 (2)

Factory Workshop Manual Make Ford Model Crown Victoria Engine and year V8-4.6L CNG SOHC VIN 9 (1999) 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 Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) P0720 - P0724: Testing and Inspection P0720 ( P 0720 ) Manual Transmission (M.T.) For diagnosis of P0720 refer to chart Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 9 For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission (A.T.) For diagnosis of P0720 refer to chart Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 10 3 Of 7 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 11 P0720 - P0724: Testing and Inspection P0721 ( P 0721 ) Manual Transmission (M.T.) For diagnosis of P0721 refer to chart Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 12 For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission (A.T.) For diagnosis of P0721 refer to chart Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 13 3 Of 7 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 20 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) Alarm Module: Service and Repair Module - Passive Anti-Theft System (PATS) REMOVAL 1. Disconnect the battery ground cable. CAUTION ^ Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded in to the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH instrument panel insulator. 1 Remove the pin-type retainers. 2 Remove the LH instrument panel insulator. 3. Remove the lower steering column cover. 1 Remove the screws. 2. Remove the lower steering column cover. 4. Remove the lower steering column cover reinforcement 1 Remove the screws. 2 Remove the lower steering column cover reinforcement. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 23 5. Remove the Passive Anti-Theft System (PATS) module and bracket. 1 Remove the bolts. 2 Disconnect the electrical connector. INSTALLATION 1. To install,reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. ^ Prior to starting the vehicle, check for PATS Diagnostic Trouble Codes (DTCs). Perform the appropriate pinpoint test. ^ When the PATS module is replaced, both ignition keys must be relearned and stored in memory. Insert each key in the ignition and turn to RUN for automatic programming. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 24 Alarm Module: Service and Repair Module - Passive Anti-Theft Transceiver REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. NOTE: The steering wheel has been removed for clarity. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 25 5. Remove LH instrument panel insulator. 1 Remove the pin-type retainers. 2 Remove the insulator. 6. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. 7. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 8. Remove the transceiver assembly. 1 Remove the screw. 2 Release the transceiver over the rib on the lock cylinder housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 26 NOTE: Only apply pressure below the key cylinder rib. 3 Disconnect the electrical connector locator and electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. ^ No key replacement or re-initialization needs to occur with the removal or installation of a new PATS transceiver. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Description and Operation Multifunction Electronic Control Module: Description and Operation The multifunction modules consist of the following: ^ Air Suspension Control Module ^ Driver Door Module (DDM) ^ Lighting Control Module (LCM) The air suspension control module is linked to its own Data Link Connector (DLC). The air suspension control module controls the air suspension and the Electronic Variable Orifice (EVO) steering. The Driver Door Module (DDM) is connected on the International Standards Organization (ISO) 9141 communication network. The DDM controls many functions including power windows, power door locks and remote keyless entry. The Lighting Control Module (LCM) is connected on the ISO 9141 communication network. The LCM controls both interior and exterior lighting, back lighting, the battery saver and warning chimes. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Description and Operation > Page 30 Multifunction Electronic Control Module: Testing and Inspection For Air Suspension concerns, See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic ) For Electronic Variable Orifice (EVO) Steering concerns, For Warning Chime concerns, See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device For Lighting concerns, See: Lighting and Horns For Power Window or Defroster concerns, See: Windows and Glass For Power Door Lock concerns, See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module Multifunction Electronic Control Module: Service and Repair Air Suspension Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Lower the instrument panel lower insulator. 1 Remove the pin-type retainers. 2 Lower the instrument panel lower insulator. 3. Remove the instrument panel lower insulator. 1 Disconnect the power point electrical connector. 2 Remove the footwell lamp. 3 Remove the instrument panel lower insulator. 4. Remove the air suspension module. 1 Disconnect the electrical connectors. 2 Remove the air suspension module. ^ Release the spring clips to remove the module from the bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 33 Multifunction Electronic Control Module: Service and Repair Driver Door Module REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door trim panel. 3. Remove the Driver Door Module (DDM). 1 Disconnect the electrical connector. 2 Remove the screws. 3. Release the locking tab. INSTALLATION CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 34 Multifunction Electronic Control Module: Service and Repair Lighting Control Module REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH instrument panel lower insulator. 1 Remove the pin-type retainers. 2 Disconnect the courtesy lamp. 3 Remove the LH instrument panel insulator. 3. Position the LCM aside. 1 Remove the locking tab. 2 Release the locking tab. 3 Position the LCM aside. 4. Remove the LCM. 1 Disconnect the electrical connectors. 2 Remove the LCM. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 35 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 41 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 42 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 43 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 44 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 45 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 46 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 47 Power Door Lock Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 48 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 49 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 50 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 51 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 52 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 53 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 54 Power Door Lock Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 55 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 56 Power Door Lock Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 57 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 58 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 59 Power Door Lock Control Module: Service and Repair REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door trim panel. 3. Remove the Driver Door Module (DDM). 1 Disconnect the electrical connector. 2 Remove the screws. 3. Release the locking tab. INSTALLATION CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Mirror Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 65 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 66 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 67 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 68 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 69 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Power Mirror Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 71 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 72 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 73 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 74 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 75 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 76 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 77 Power Mirror Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 78 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 79 Power Mirror Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 80 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 81 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Seat Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 86 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 87 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 88 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 89 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 90 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 91 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 92 Power Seat Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 93 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 94 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 95 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 96 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 97 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 98 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 99 Power Seat Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 100 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 101 Power Seat Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 102 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 103 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications Anti-Lock Brake Control Module: Specifications Retaining Screws ................................................................................................................................. ................................................................. 1.8-2.8 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 108 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 109 Anti-Lock Brake Control Module: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. - Disconnect the control module electrical connector. - Disconnect the pump motor electrical connector. 3. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the module. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 119 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 120 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis Drive/Propeller Shaft: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis Article No. 01-1-14 01/22/01 ^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) ^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) FORD: 1999-2001 CROWN VICTORIA MERCURY: 1999-2001 GRAND MARQUIS ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph) which may be related to driveshaft, axle, wheels, or their components. ACTION Identify the causal component for the vibration and balance or replace as necessary to eliminate the vibration. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 126 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 127 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 128 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 129 For Dealerships with An Electronic Vibration Analyzer Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration conditions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 130 Driveline Vibration Data Sheet OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing Drive/Propeller Shaft: All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 135 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 136 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 01-1-14 > Jan > 01 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 01-1-14 > Jan > 01 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 146 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 01-1-14 > Jan > 01 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 147 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 158 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 159 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 165 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 166 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 170 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 175 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 176 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 181 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 182 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 185 Control Module HVAC: Diagrams Electronic Climate Control Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control Control Module HVAC: Description and Operation Blower Motor Speed Control The A/C blower motor speed control is located on the A/C evaporator housing, in the engine compartment. - The function of the A/C blower motor speed control is to convert low power signals from the electronic automatic temperature control module to a high current, variable ground feed for the blower motor. - Blower motor speed is infinitely variable and is controlled by the electronic automatic temperature control module software. - A delay function provides a gradual increase or decrease in blower motor speed under all conditions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control > Page 188 Control Module HVAC: Description and Operation Electronic Climate Control Module The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: - a blower speed override control for manual input - a vacuum fluorescent display for displaying set temperature, ambient temperature, function and Diagnostic Trouble Codes (DTCs) - an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes (DTCs). These DTCs direct the technician to the inoperative component. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control Control Module HVAC: Service and Repair Blower Motor Speed Control REMOVAL 1. Disconnect the wire harness connector. 2. Drain the cooling system below the heater hoses. 3. Disconnect the heater hose. 4. Remove the screws and remove the blower motor speed control. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 191 Control Module HVAC: Service and Repair Electronic Climate Control Module REMOVAL 1. Remove the finish panel. 2. Disconnect the connector. 3. Remove the screws and pull the Electronic Automatic Temperature Control (EATC) module from the instrument panel. 4. Remove the EATC module. - Remove the nuts and the vacuum harness. - Disconnect the wire harness connectors and remove the EATC module. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 192 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module Audible Warning Device Control Module: Diagrams Lighting Control Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module > Page 198 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module > Page 199 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) > Component Information > Description and Operation Fuel Gauge Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 203 Fuel Gauge Module (CNG): Testing and Inspection The Compressed Natural Gas fuel level indicator system is a function of the Natural Gas Vehicle (NGV) module. For Testing and Inspection procedures, Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 204 Fuel Gauge Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 205 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 206 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Module Bolt 27 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 211 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 212 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Remove the battery ground cable. 2. Remove the sight shield. ^ Twist the clips. 3. Remove the Daytime Running Lamps (DRL) module 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the DRL module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing Exterior Lighting Module: Customer Interest Turn Signals - Intermittent Rapid Flashing Article No. 02-9-7 05/13/02 ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY FORD: 1998-2002 CROWN VICTORIA MERCURY: 1998-2002 GRAND MARQUIS This article is being republished in its entirety to update the Service Procedure and to update the parts required. ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn signal fast flash is not due to bulb outage, then verify good continuity at all ground screws. ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part. Refer to the following Service Procedure for details. SERVICE PROCEDURE If normal diagnostics does not correct the condition, replace the Lighting Control Module with the latest engineering level as follows: 1 Disconnect the battery ground cable. For additional information refer to Workshop Manual Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year. 2. Remove the LH instrument panel lower insulator (Figure 1). a. Remove the pin-type retainers (Figure 1, Detail 1). b. Disconnect the courtesy lamp (Figure 1, Detail 2). 3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and shaft. For additional information, refer to Section 310-02 of the Workshop Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 221 4. Position the LCM aside. a. Remove the screws (Figure 2, Detail 1). b. Release the locking tab (Figure 2, Detail 2). 5. Disconnect the electrical connectors and remove the LCM (Figure 3). 6. To install, reverse the removal procedure. Check for correct operation. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-21-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 222 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing Exterior Lighting Module: All Technical Service Bulletins Turn Signals - Intermittent Rapid Flashing Article No. 02-9-7 05/13/02 ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY FORD: 1998-2002 CROWN VICTORIA MERCURY: 1998-2002 GRAND MARQUIS This article is being republished in its entirety to update the Service Procedure and to update the parts required. ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn signal fast flash is not due to bulb outage, then verify good continuity at all ground screws. ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part. Refer to the following Service Procedure for details. SERVICE PROCEDURE If normal diagnostics does not correct the condition, replace the Lighting Control Module with the latest engineering level as follows: 1 Disconnect the battery ground cable. For additional information refer to Workshop Manual Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year. 2. Remove the LH instrument panel lower insulator (Figure 1). a. Remove the pin-type retainers (Figure 1, Detail 1). b. Disconnect the courtesy lamp (Figure 1, Detail 2). 3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and shaft. For additional information, refer to Section 310-02 of the Workshop Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 228 4. Position the LCM aside. a. Remove the screws (Figure 2, Detail 1). b. Release the locking tab (Figure 2, Detail 2). 5. Disconnect the electrical connectors and remove the LCM (Figure 3). 6. To install, reverse the removal procedure. Check for correct operation. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-21-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 229 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1 > Page 234 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 238 Horn Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 239 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 244 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 245 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 246 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 247 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 248 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 249 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 250 Interior Lighting Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 251 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 252 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 253 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 254 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 255 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 256 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Interior Lighting Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 258 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 259 Interior Lighting Module: Electrical Diagrams Diagram 58-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 260 Diagram 58-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 261 Diagram 58-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Lamp Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 266 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 267 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 268 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 269 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 270 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 271 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 272 Lamp Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 273 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 274 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 275 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 276 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 277 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 278 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 279 Lamp Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 280 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 281 Lamp Control Module: Electrical Diagrams Diagram 58-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 282 Diagram 58-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Diagram 58-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 284 Lamp Control Module: Description and Operation The Lighting Control Module (LCM) eliminates the electronic interference and heat associated with the thermoelectric devices used previously. The LCM is a microprocessor based module that controls several vehicle subsystems. It responds to electrical signals from various switches, sensors, and external modules. LCM subsystem function include: ^ headlamps with autolamps ^ turn signal lamps/hazard flasher lamps ^ cornering lamps ^ parking lamps ^ courtesy lamps ^ demand lamps ^ battery saver ^ backlighting ^ interfacing with the driver door module via SCP for illuminated entry. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 285 Lamp Control Module: Service and Repair REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH instrument panel lower insulator. 1 Remove the pin-type retainers. 2 Disconnect the courtesy lamp. 3 Remove the LH instrument panel insulator. 3. Position the LCM aside. 1 Remove the locking tab. 2 Release the locking tab. 3 Position the LCM aside. 4. Remove the LCM. 1 Disconnect the electrical connectors. 2 Remove the LCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 286 CAUTION: Once the new module is installed, it is necessary to download the module configuration information from New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 291 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 295 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 301 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 308 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 309 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 310 Powertrain Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 311 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 312 Powertrain Control Module: Specifications Powertrain Control Module Electrical Connector Bolt 4-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 315 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 316 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 317 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 318 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 319 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 320 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 321 Powertrain Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 322 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 323 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 324 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 325 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 326 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 327 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 328 Powertrain Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 329 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 330 Powertrain Control Module: Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 333 Powertrain Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 334 Powertrain Control Module: Removal and Replacement Compressed Natural Gas Vehicle (NGV) Module REMOVAL WARNING - DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. - IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 335 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 336 1. To install, reverse the removal procedure. - Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Gasoline REMOVAL 1. Disconnect the battery ground cable. 2. Remove the screw and position the powertrain control module electrical connector out of the way. 3. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 337 4. Remove the powertrain control module cover. 5. Remove the three pin-type retainers and the under dash sight cover. 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 341 Fuel Injector Driver Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 342 Fuel Injector Driver Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 343 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 344 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 350 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 355 Fuel Injector Driver Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 356 Fuel Injector Driver Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 357 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 358 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page 362 Fuel Valve Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page 363 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 369 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations > Page 374 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Air bag Electronic Crash Sensor (ECS) module bolts .................................................................................................................................. 12 Nm (9 Lb-Ft) Driver air bag module bolts .................................................................................................................. ........................................................ 12 Nm (9 Lb-Ft) Passenger air bag module bolts ....................... .............................................................................................................................................. 9 Nm (80 Lb-In) Air bag sensor bolts .................................................................................................................. .................................................................... 12 Nm (9 Lb-Ft) Aft steering column nuts ....................... ...................................................................................................................................................... 15 Nm (11 Lb-Ft) Forwarded Steering column nuts ................................................................................. .............................................................................. 15 Nm (11 Lb-Ft) Crash sensor grounding screw weld nut repair screw (8 mm) ....................................................................................................................... 12 Nm (9 Lb-Ft) Grounding screw (6 mm) ..................................................................................................................... ......................................................... 12 Nm (9 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 379 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 380 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 381 Air Bag Control Module: Service Precautions WARNING: - The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have deployed. In addition, make sure the area of the (ECS) mounting is restored to its original condition. - If installing a new air bag module, always install a new air bag electronic crash sensor (ECS) module. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 382 Air Bag Control Module: Description and Operation The air bag Electronic Crash Sensor (ECS) module performs the following functions: - signals the inflators to deploy the air bags in the event of a deployable crash. - monitors the air bag Supplemental Restraint System (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). - signals the Lighting Control Module (LCM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the ECS and is not serviced separately. The ECS monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the ECS will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will flash the two-digit LFC. The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The ECS will also communicate the current and historical DTCs the DLC, using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system detects a fault condition, the ECS will signal the LCM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After the fault has been corrected, the next highest priority fault will be displayed. The ECS includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors close. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 383 Air Bag Control Module: Service and Repair REMOVAL WARNING: - The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have deployed. In addition, make sure the area of the (ECS) mounting is restored to its original condition. - If installing a new air bag module, always install a new air bag electronic crash sensor (ECS) module. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the RH sill plate. 3. Position the carpet out of the way. 4. Remove the ECS. 1 Disconnect the ECS electrical connector locking clip. 2 Disconnect the ECS electrical connector. 3 Remove the three retaining screws. 4 Remove the ECS module and bracket. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 384 1. Follow the removal procedure in reverse order. WARNING: The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have deployed. In addition, make sure the area of the (ECS) mounting is restored to its original condition. - If installing a new air bag module, always install a new air bag electronic crash sensor (ECS) module. - The tightening torque of the air bag electronic crash sensor (ECS) module bracket retaining screws is critical for correct system operation. NOTE: Make sure to tighten the retaining bolts to specification. - A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 389 The Starter Relay is located in the High Current Relay Center. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 390 Starter Relay: Description and Operation The starter relay: - is a mini ISO relay. - switches power to the starter solenoid to engage the starter motor when it receives a START signal from the ignition switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 391 Starter Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 392 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 393 Starter Relay: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Press the clips inward and open the relay junction box. 3. Remove the ISO starter relay. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations Electronic Variable Orifice Steering Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations > Page 399 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations > Page 400 Electronic Variable Orifice Steering Module: Service and Repair Removal 1. Lower the panel. 2. Remove the lamp from the panel and disconnect the wiring. 3. Remove the screws. 4. Disconnect the wiring and remove the control module. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 405 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 406 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Retaining Screws ................................................................................................................................. ..................................... 2.3-3.3 Nm (20-29 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 410 Suspension Control Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 411 Suspension Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 412 Suspension Control Module: Description and Operation A microprocessor controls the air suspension system. The microprocessor and its supporting hardware are contained in the air suspension control module. The air suspension control module responds to signals from various sensors in the vehicle to maintain the programmed ride height while the vehicle is either moving or stopped. The air suspension control module accomplishes this by opening and closing solenoid valves to control the amount of air in the air spring(s). The air suspension control module turns on the compressor by applying voltage through the compressor relay to inflate the air spring(s) and raise the vehicle. The air suspension control module opens the vent solenoid to lower the vehicle by releasing air from the air spring(s)in response to signal inputs from the air suspension height sensor(s). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 413 Suspension Control Module: Service and Repair Removal WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Pull out the lower instrument panel insulator. 1 Remove the pushpins. 2 Pull out the lower instrument panel insulator. 4. Remove the lower instrument panel insulator. 1 Disconnect the power point. 2 Disconnect the courtesy lamp. 3 Remove the lower instrument panel insulator. 5. Remove the rear air suspension control module. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the rear air suspension control module. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 414 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 419 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 420 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions One Touch Window Down Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 425 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 426 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 427 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 428 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 429 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 430 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 431 One Touch Window Down Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 432 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 433 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 434 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 435 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 436 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 437 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 438 One Touch Window Down Module: Connector Views Driver Door Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 439 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 440 One Touch Window Down Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 441 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 442 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Page 443 One Touch Window Down Module: Service and Repair REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door trim panel. 3. Remove the Driver Door Module (DDM). 1 Disconnect the electrical connector. 2 Remove the screws. 3. Release the locking tab. INSTALLATION CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 448 Wiper Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the tunnel brace trim cover. 1 Remove pin-type retainers. 2 Remove the tunnel brace trim cover. 3. Position the instrument panel ash receptacle aside. 1 Remove the screws. 2 Position the instrument panel ash receptacle aside. 4. Remove the instrument panel ash receptacle assembly. 1 Disconnect the electrical connector. 2 Remove the instrument panel ash receptacle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 449 5. Remove the windshield wiper control module. 1 Remove the screw. 2 Disconnect the electrical connector. 3 Remove the windshield wiper control module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Fuel Door Lock Switch > Component Information > Description and Operation Fuel Door Lock Switch: Description and Operation The fuel filler door lock switch: - actuates a solenoid integral to the fuel filler door latch to release the fuel filler door. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 464 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch Power Door Lock Switch: Testing and Inspection LF Door Lock Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 467 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 468 Power Door Lock Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 469 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Page 470 Power Door Lock Switch: Service and Repair REMOVAL 1. Remove the window regulator switch plate. 2. Remove the screws. 3. Disconnect the connector. 4. Remove the door lock switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 474 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 475 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 476 Power Mirror Switch: Service and Repair REMOVAL 1. Remove the window regulator switch plate from the front door trim panel. CAUTION: Use a shop towel or similar material between the tool and the front door trim panel or damage to the front door trim panel may occur. 2. Release the tabs. 3. Remove the exterior rear view mirror control switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch Power Seat Switch: Diagrams Driver's Seat Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch > Page 481 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch Power Seat Switch: Testing and Inspection Driver's Seat Control Switch Driver Seat Control Switch (All Others) Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 484 Schematic Driver Seat Control Switch (Base and Police) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 485 Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 486 Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 487 Power Seat Switch: Testing and Inspection Passenger Seat Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 488 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 489 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch Power Seat Switch: Service and Repair Front Seat Occupied Switch REMOVAL 1. Disconnect the battery. 2. Remove the seat. 3. Remove the seat track. 4. Disconnect the connector. 5. Slide the retainers outboard. 6. Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch > Page 492 Power Seat Switch: Service and Repair Lumbar Seat Control Switch REMOVAL 1. Disconnect the battery. 2. Remove the seat. 3. Remove the cover. 4. Remove the screws. 5. Disconnect the connector. 6. Disconnect the vacuum tubes. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch > Page 493 NOTE: Mark the tubes before disconnecting. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch > Page 494 Power Seat Switch: Service and Repair Seat Regulator Control Switch REMOVAL 1. Disconnect the battery. 2. Remove the front door trim panel. 3. Remove the seat regulator control switch. 1 Remove the screws. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Measured using Rotunda EEC-IV 60-Pin Breakout Box Front and Rear 800-1400 ohms Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 500 Wheel Speed Sensor: Mechanical Specifications Retaining Bolts Front 36-53 in.lb Rear 14-19 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Removal 1. Disconnect the front anti-lock brake sensor electrical connector. 2. Raise and support the vehicle. 3. Remove the routing clips. 4. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the sensor. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 503 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 504 Wheel Speed Sensor: Service and Repair Rear Removal 1. Remove rear seat bottom. 2. Disconnect the rear anti-lock brake sensor electrical connector. 3. Push the sensor harness grommet through the passenger compartment floor. 4. Raise and support the vehicle. 5. Disconnect the routing clips. 6. Remove the rear anti-lock brake sensor. 1 Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 505 2 Remove the sensor. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 16-24 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 517 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the lower intake manifold. 2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor. 3. If necessary, remove the wiring connector. 4. Remove the cylinder head temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Service and Repair Engine Coolant Temperature Sender: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Partially drain the engine cooling system. 2. Remove the water temperature indicator sender unit. 1 Disconnect the electrical connector. 2 Remove the water temperature indicator sender unit. Installation 1. Install the water temperature indicator sender unit. 1 Install the water temperature indicator sender unit. 2 Connect the electrical connector. 2. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Diagrams > Page 525 Deactivator Switch: Adjustments NOTE: For proper adjustment, the deactivator switch must be removed and reinstalled. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch Deactivator Switch: Service and Repair Brake Pedal Position (BPP) Switch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower insulator. 1 Remove the push pins. 2 Disconnect the interior lamp. 3 Remove the lower insulator. 3. Disconnect the Brake Pedal Position (BPP) switch. 4. Remove the BPP switch. 1 Remove the cotter pin. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 528 2 Remove the sleeve. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 529 Deactivator Switch: Service and Repair Deactivator Switch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the deactivator switch. 1 Disconnect the electrical connector. 2 Rotate counterclockwise and remove the deactivator switch. INSTALLATION 1. Pull the plunger out to its full travel. 2. Fully depress the brake pedal. 3. Install the deactivator switch. 1 Position the deactivator switch in the bracket and rotate clockwise. 2 Connect the electrical connector. 4. Slowly release the brake pedal. 5. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the steering wheel cover screws. 3. Remove the steering wheel cover. 1 Position the steering wheel cover aside. 2 Disconnect the electrical connector and wire harness from the steering wheel cover. 3 Remove the steering wheel cover. 4. Remove the speed control actuator switches. 1 Push the speed control actuator switches out towards the face of the steering wheel. 2 Position the speed control actuator switches through the steering wheel openings and remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Engine Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Engine Oil Pressure Switch: Locations 1. Oil Pressure Sensor 2. Oil Pressure Sensor Connector Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Engine Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Page 537 Engine Oil Pressure Switch: Service and Repair Removal 1. Remove the oil pressure sensor oil pressure sensor: 1 Disconnect the wire. 2 Remove the oil pressure sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Air Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Description and Operation Ambient Air Temperature Sensor: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Air Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Description and Operation > Page 542 Ambient Air Temperature Sensor: Service and Repair REMOVAL 1. Remove the radiator upper sight shield. 2. Disconnect the wire harness connector. 3. Remove the A/C ambient air temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > In-Car Temperature Sensor <--> [Cabin Temperature Sensor / Switch] > Component Information > Description and Operation In-Car Temperature Sensor: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the A/C evaporator housing and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow takes air from the A/C evaporator housing air stream to create a suction in the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > In-Car Temperature Sensor <--> [Cabin Temperature Sensor / Switch] > Component Information > Description and Operation > Page 546 In-Car Temperature Sensor: Service and Repair REMOVAL 1. Remove the finish panel. 2. Disconnect the connector. 3. Remove the screws and pull the control assembly away from the instrument panel. 4. Remove the screws and position the in-car temperature sensor to access the connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > In-Car Temperature Sensor <--> [Cabin Temperature Sensor / Switch] > Component Information > Description and Operation > Page 547 5. Disconnect the connector. 6. Disconnect the hose and remove the in-car temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Pressure Cut-off Switch ..................................................................................................................................................... 6.8-13.6 N.m (61-120 Lb-In) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 552 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Close ................................................................................................................................................... .................................... 276-324 kPa (40-47 psi) Open ....................................................................... ................................................................................................................ 152-193 kPa (22-28 psi) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the A/C compressor to condenser discharge line. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 555 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the suction accumulator/driver. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction or low side pressure to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the wire harness connector. 2. Remove the A/C cycling switch. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 558 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the wire harness connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top RH side of the instrument panel above the glove compartment. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Page 562 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the wire harness connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Warning Switch <--> [Key Reminder Switch] > Component Information > Service and Repair Key Warning Switch: Service and Repair REMOVAL 1. Remove the ignition lock cylinder. 1 Insert the key into the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Release the clip. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure ^ Verify ignition lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 571 Ambient Light Sensor: Service and Repair REMOVAL 1. Unclip the instrument panel upper finish panel. 2. Disconnect the light sensor amplifier electrical connector. CAUTION: To avoid damaging the light sensor amplifier electrical connector, carefully tilt the panel to expose the connector without stretching the wiring. 3. Unclip the light sensor amplifier. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 583 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 589 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 590 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 591 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove LH instrument panel insulator. 1 Remove the pin-type retainers. 2 Remove the LH instrument panel insulator. ^ Disconnect the courtesy lamp. 3. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 4. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the (A) BPP switch from the (B) brake master cylinder push rod. 3 Remove the brake master cylinder push rod spacer. 4 Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 595 Hazard Warning Switch: Description and Operation PRINCIPLES OF OPERATION The hazard flasher switch (part of the multifunction switch) is located on the top of the steering column, forward of the steering wheel. ^ The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the switch top. ^ The switch should produce an audible click when it toggles from one state to another. ^ The switch should extend markedly further above the column when the switch is ON than it does when it is OFF. When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the two turn indicators in the instrument cluster will flash simultaneously. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Component Test Hazard Warning Switch: Testing and Inspection Component Test Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Component Test > Page 598 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Component Test > Page 599 Hazard Warning Switch: Testing and Inspection Operational Test The hazard flasher switch (part of the multifunction switch) is located on the top of the steering column, forward of the steering wheel. - The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the switch top. - The switch should produce an audible click when it toggles from one state to another. - The switch should extend markedly further above the column when the switch is ON than it does when it is OFF. When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the two turn indicators in the instrument cluster will flash simultaneously. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 600 Hazard Warning Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 601 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 602 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 606 Headlamp Dimmer Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 607 Headlamp Dimmer Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 608 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 609 Headlamp Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 610 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 611 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Main Light Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 615 Main Light Switch: Description and Operation The headlamp switch is a multi-position switch. ^ The positions include OFF, PARK, and HEAD. ^ With the headlamp switch in the PARK position (first detent), a signal is supplied to the LCM which powers the front parking lamps, the tail lamps, the side marker lamps, and the license lamp. ^ With the headlamp switch in the HEAD position, power is supplied to the headlamps through the LCM and the multifunction switch. ^ The panel dim switch (part of the headlamp switch) is located above the headlamp switch. The panel dim switch operates only with the parking lamps or headlamps on. ^ When the panel dim switch is held in the up position, the instrument panel lighting will progressively brighten. ^ When the panel dim switch is held in the down position, the instrument panel lighting will progressively dim. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 616 Main Light Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 617 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 618 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 619 Main Light Switch: Service and Repair REMOVAL 1. Remove the instrument panel cluster finish panel. 2. Remove the headlamp switch. ^ Unclip the switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL AND INSTALLATION NOTE: The horn switch is integral to the driver side air bag module and cannot be replaced separately. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams Multifunction Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 626 Multifunction Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 627 Multifunction Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 628 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 629 Multifunction Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 630 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 631 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 646 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 647 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 653 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 654 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 655 Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Bolts 4-5 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 656 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 657 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Loosen the clamp and remove the air cleaner outlet tube. 4. Remove the four bolts and the mass air flow sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 658 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 662 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 16-24 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 669 Crankshaft Position Sensor: Description and Operation The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 670 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the two bolts and position the A/C compressor out of the way. 6. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 671 7. Remove the crankshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 675 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the lower intake manifold. 2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor. 3. If necessary, remove the wiring connector. 4. Remove the cylinder head temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications Fuel Tank Pressure Sensor: Specifications Fuel Tank Pressure Sensor 55 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications > Page 679 Fuel Tank Pressure Sensor: Service and Repair NOTE: Perform the Fuel Pressure Release Procedure prior to making any repairs. REMOVAL 1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box. 3. Remove the NGV fuel tank pressure sensor. 1 Disconnect the NGV fuel tank pressure sensor electrical connector. 2 Remove the NGV fuel tank pressure sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. ^ Replace the NGV fuel tank pressure sensor O-ring seal. ^ Lubricate the NGV fuel tank pressure sensor O-ring seal with Super Premium 5W30 engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to help seal and ease the installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Nut 20-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 683 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower intake manifold. 3. Disconnect the electrical connector from the Knock Sensor (KS). 4. Remove the nut and the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 688 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 689 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 690 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 691 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 692 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 693 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 694 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 695 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 696 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 697 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 698 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 699 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 700 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 701 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Emissions/Engine Controls - Driveability Diagnosis > Page 702 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Page 703 Oxygen Sensor: Specifications Heated Oxygen Sensor - Front (HO2S) 36-46 Nm Heated Oxygen Sensor - Rear (HO2S) 36-46 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Page 704 H02S Location Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 708 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 710 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 712 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 714 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 715 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 716 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 717 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 718 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 719 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Front Oxygen Sensor: Service and Repair Front EGO Sensor Wrench Special Tool(s) REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the right side Heated Oxygen Sensor (HO2S). 3. Disconnect the electrical connector from the left side heated oxygen sensor. 4. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Front > Page 722 5. Remove the front heated oxygen sensors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L49-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the heated oxygen sensors prior to installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Front > Page 723 Oxygen Sensor: Service and Repair Rear EGO Sensor Wrench Special Tool(s) REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the electrical connector from the rear Heated Oxygen Sensor (HO2S). 4. Remove the rear heated oxygen sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Front > Page 724 1. To install, reverse the removal procedure. NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L494AA or equivalent meeting Ford specification ESE-M12A4A to the threads of the heated oxygen sensors prior to installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR 5-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 728 Pressure Feedback Exhaust Sensor: Description and Operation The EGR transducer: ^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube ^ sends an EGR flow rate signal to the powertrain control module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 729 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Disconnect the engine control sensor wiring. 4. Remove the two hoses. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 730 5. Remove the two nuts and the differential pressure feedback EGR valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine appearance cover. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the throttle position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 737 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 738 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Loosen the digital Transmission Range (TR) bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 739 7. Tighten the bolts. 8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR sensor electrical connector. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 740 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 746 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 747 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 748 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 749 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 750 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 751 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 752 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 753 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 754 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 755 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 756 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 757 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 758 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR 5-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 763 Pressure Feedback Exhaust Sensor: Description and Operation The EGR transducer: ^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube ^ sends an EGR flow rate signal to the powertrain control module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 764 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Disconnect the engine control sensor wiring. 4. Remove the two hoses. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 765 5. Remove the two nuts and the differential pressure feedback EGR valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 775 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 776 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 782 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 783 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 784 Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Bolts 4-5 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 785 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 786 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Loosen the clamp and remove the air cleaner outlet tube. 4. Remove the four bolts and the mass air flow sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 787 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Specifications Fuel Temperature Sensor: Specifications Fuel Tank Temperature Sensor 40 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Upper) Sensor REMOVAL NOTE: The upper fuel tank temperature sensor is also referred to as fuel tank temperature sensor No.1. 1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box. 3. Remove the upper NGV fuel tank temperature sensor. 1 Disconnect the electrical connector. 2 Remove the fuel tank temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor > Page 793 Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Lower) Sensor REMOVAL NOTE: The lower fuel tank temperature sensor is also referred to as fuel tank temperature sensor No.2. 1. Carry out the Pressure Relief Fuel Line Venting procedure. 2. Raise and support the vehicle. 3. Remove the lower NGV fuel tank shield upper nuts. 4. Remove the lower NGV fuel tank shield. 1 Remove the nuts. 2 Remove the lower NGV fuel tank shield. 5. Remove the lower NGV fuel tank temperature sensor. 1 Disconnect the lower NGV fuel tank temperature sensor electrical connector. 2 Remove the lower NGV fuel tank temperature sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor > Page 794 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy ^ Replace the lower NGV fuel tank temperature sensor O-ring seal. ^ Lubricate the lower NGV fuel tank temperature sensor O-ring seal with Super Premium 5W30 engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to help seal and ease the installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement Technical Service Bulletin # 99B03 Date: 990301 Campaign - Inertia Switch Bracket Replacement 99B03 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch Original - March, 1999 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - May, 1999 1998-99 Crown Victoria/Grand Marquis - Inertia Switch IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 803 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 804 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 99B03 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hr. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 805 Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal processing channels. Inertia Bracket Kit: XW7Z-9D379-AA CLAIMS PREPARATION -- Entering using DWE -- Use code information shown below: ^ Program Code - 99B03 ^ Labor Operation - See above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE PROCEDURE 1. Open trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 806 2. Remove carpet pushpins from left inner quarter panel. See Figure 1. 3. Pull carpet away from left inner quarter panel. 4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner quarter panel reinforcement. Refer to Figure 2. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 807 5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an assembly. 6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT disconnect inertia switch electrical connector. 7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes. 8. Measure, mark and drill bottom anti-rotation hole as follows: ^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3. ^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at this location. ^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new location. ^ Using a 25/64 inch drill bit, drill hole at center punched location. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 808 9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4. 10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these locations. 11. Remove inertia switch bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 809 12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure 5. 13. Clean all metal shavings from luggage compartment. 14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft). 15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2 lb-ft). 16. Install wiring harness routing pushpins. 17. Press reset button on inertia switch. Make sure switch is set properly. 18. Reposition carpet back on left inner quarter panel. 19. Install carpet pushpins. 20. Close trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 810 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 811 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 812 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Technical Service Bulletins: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Pad: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement Technical Service Bulletin # 99B03 Date: 990301 Campaign - Inertia Switch Bracket Replacement 99B03 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch Original - March, 1999 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - May, 1999 1998-99 Crown Victoria/Grand Marquis - Inertia Switch IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 827 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 828 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 99B03 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hr. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 829 Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal processing channels. Inertia Bracket Kit: XW7Z-9D379-AA CLAIMS PREPARATION -- Entering using DWE -- Use code information shown below: ^ Program Code - 99B03 ^ Labor Operation - See above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE PROCEDURE 1. Open trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 830 2. Remove carpet pushpins from left inner quarter panel. See Figure 1. 3. Pull carpet away from left inner quarter panel. 4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner quarter panel reinforcement. Refer to Figure 2. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 831 5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an assembly. 6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT disconnect inertia switch electrical connector. 7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes. 8. Measure, mark and drill bottom anti-rotation hole as follows: ^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3. ^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at this location. ^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new location. ^ Using a 25/64 inch drill bit, drill hole at center punched location. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 832 9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4. 10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these locations. 11. Remove inertia switch bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 833 12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure 5. 13. Clean all metal shavings from luggage compartment. 14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft). 15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2 lb-ft). 16. Install wiring harness routing pushpins. 17. Press reset button on inertia switch. Make sure switch is set properly. 18. Reposition carpet back on left inner quarter panel. 19. Install carpet pushpins. 20. Close trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 834 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 835 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 836 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement Technical Service Bulletin # 99B03 Date: 990301 Campaign - Inertia Switch Bracket Replacement 99B03 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch Original - March, 1999 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - May, 1999 1998-99 Crown Victoria/Grand Marquis - Inertia Switch IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 842 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 843 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 99B03 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hr. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 844 Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal processing channels. Inertia Bracket Kit: XW7Z-9D379-AA CLAIMS PREPARATION -- Entering using DWE -- Use code information shown below: ^ Program Code - 99B03 ^ Labor Operation - See above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE PROCEDURE 1. Open trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 845 2. Remove carpet pushpins from left inner quarter panel. See Figure 1. 3. Pull carpet away from left inner quarter panel. 4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner quarter panel reinforcement. Refer to Figure 2. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 846 5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an assembly. 6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT disconnect inertia switch electrical connector. 7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes. 8. Measure, mark and drill bottom anti-rotation hole as follows: ^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3. ^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at this location. ^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new location. ^ Using a 25/64 inch drill bit, drill hole at center punched location. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 847 9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4. 10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these locations. 11. Remove inertia switch bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 848 12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure 5. 13. Clean all metal shavings from luggage compartment. 14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft). 15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2 lb-ft). 16. Install wiring harness routing pushpins. 17. Press reset button on inertia switch. Make sure switch is set properly. 18. Reposition carpet back on left inner quarter panel. 19. Install carpet pushpins. 20. Close trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 849 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 850 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 851 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Pad: Customer Interest Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Pad: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Component Information > Technical Service Bulletins > Page 864 Brake Pad: Specifications Front Rear Thickness, Min. 0.039 in 0.039 in Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Remove brake master cylinder filler cap. Check brake fluid level in brake master cylinder reservoir. Remove fluid until brake master cylinder reservoir is half full. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. CAUTION: Replace the pad if worn to or past the specified thickness above the metal backing plate or rivets. Replace the pads in complete axle sets. Inspect the pads for wear and contamination. 5. CAUTION: Do not pry in caliper sight hole to retract pistons as this can damage the pistons and boots. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose. Provide a suitable support. Remove the disc brake caliper. 1 Remove two front disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. 6. Remove the disc brake pad anti-rattle clip. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Component Information > Service and Repair > Front > Page 867 7. Measure the brake disc thickness. - Replace the brake disc if not within specification. 8. Inspect the disc brake caliper. - If leaks or damaged boots are found, disassembly is required. 9. Remove the pads and stainless steel slippers. 1 Remove the pads and verify thickness. 2 Remove the front disc brake caliper anchor plate stainless steel slippers and discard. 10. Inspect the front disc brake anchor plate assembly. - Check the guide pin boots for damage. - Check the guide pins for binding and damage. - Replace worn or damaged pins. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Component Information > Service and Repair > Front > Page 868 Installation 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads. NOTE: Replace all hardware supplied with pad kit. Install the pads. 1 Install the new front disc brake caliper anchor plate stainless steel slippers. 2 Install the pads. 2. NOTE: Use a wood block or used pad to protect pistons and boots. Compress the caliper pistons. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Component Information > Service and Repair > Front > Page 869 3. Install the disc brake pad anti-rattle clip. 4. CAUTION: Use care not to damage the bleeder screw or brake disc shield. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 5. Install the wheel and tire assembly. 6. Lower the vehicle. 7. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. Install brake master cylinder filler cap. 8. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Inspect brake operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Component Information > Service and Repair > Front > Page 870 Brake Pad: Service and Repair Rear Removal 1. Inspect the brake pads for wear or contamination. Install new if worn to or past specification. 2. NOTE: It is not necessary to remove the rear wheel brake hose when performing this procedure. Remove the rear disc brake caliper. 3. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads. Remove the brake pads by pushing inward and rotating the pad up. 4. NOTE: Use a block of wood or used pad to protect the piston and boots. Retract the caliper piston into the rear disc brake caliper. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Component Information > Service and Repair > Front > Page 871 5. Make sure the slippers are clean and in good condition. Installation 1. CAUTION: Install the brake pads in full axle sets. Do not replace worn brake pads on only one side of vehicle. Install the brake pads. 2. Install the rear disc brake caliper. 3. Verify correct brake operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Component Information > Page 872 Brake Pad: Specifications Front Rear Thickness, Min. 0.039 in 0.039 in Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine appearance cover. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the throttle position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 880 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 884 Crankshaft Position Sensor: Description and Operation The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 885 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the two bolts and position the A/C compressor out of the way. 6. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 886 7. Remove the crankshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 892 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 893 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 894 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 895 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 896 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 897 Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Functional > Page 900 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Service Precautions WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Functional > Page 901 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the steering column lock housing bearing and steering column lock gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing bearing. ^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three o'clock position. Rotate it counterclockwise. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Functional > Page 902 2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install the steering wheel. 4. Install the ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Nut 20-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 906 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower intake manifold. 3. Disconnect the electrical connector from the Knock Sensor (KS). 4. Remove the nut and the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air bag Electronic Crash Sensor (ECS) module bolts .................................................................................................................................. 12 Nm (9 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 911 Impact Sensor: Service Precautions WARNING: - Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 912 Impact Sensor: Service and Repair REMOVAL WARNING: - Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator upper sight shield. 3. Remove the air bag sensor. 1 Disconnect the air bag sensor electrical connector. 2 Remove the three screws. 3 Remove the air bag sensor. INSTALLATION 1. Follow the removal procedure in reverse order. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle shop manual to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 913 auxiliary batteries and power supplies (if equipped). NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 920 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 921 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 922 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 923 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 924 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 925 Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 928 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Service Precautions WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 929 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the steering column lock housing bearing and steering column lock gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing bearing. ^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three o'clock position. Rotate it counterclockwise. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 930 2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install the steering wheel. 4. Install the ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Shock Absorber Electronic Steering Sensor Screws ...................................................................................................................... ............................................. 1 Nm (9 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 939 Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module to avoid overcompensation of the air suspension during turns. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 940 Steering Angle Sensor: Service and Repair Removal 1. Remove the screws. 2. Remove the sound panel. 3. Remove the finish panel. 4. Remove the knee bolster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 941 5. Remove the bracket. 6. Remove the sensor. 1 Disconnect the wiring. 2 Remove the screws. 3 Remove the sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications Ride Height Sensor: Specifications Mounting Bracket To Lateral Arm ........................................................................................................................................................... 14 Nm (10 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 946 Ride Height Sensor: Description and Operation The air suspension height sensor sends signals to the air suspension control module. There are three possible conditions that the air suspension control module interprets from the signals of the air suspension height sensors. The conditions are trim height, below trim height, or above trim height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 947 Ride Height Sensor: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Turn the air suspension switch off. 3. Raise and support the vehicle. 4. Disconnect the air suspension height sensor electrical connector. 5. Remove the air suspension height sensor. ^ Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Shock Absorber Electronic Steering Sensor Screws ...................................................................................................................... ............................................. 1 Nm (9 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 951 Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module to avoid overcompensation of the air suspension during turns. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 952 Steering Angle Sensor: Service and Repair Removal 1. Remove the screws. 2. Remove the sound panel. 3. Remove the finish panel. 4. Remove the knee bolster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 953 5. Remove the bracket. 6. Remove the sensor. 1 Disconnect the wiring. 2 Remove the screws. 3 Remove the sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation Suspension Mode Switch: Description and Operation CAUTION: The air suspension switch must be turned to the OFF position when the vehicle is hoisted, jacked, towed, jump started, or raised off the ground, to avoid unnecessary operation of the system and possible damage to the air suspension system components. The air suspension switch provides a signal to the air suspension control module in the ON position to activate the system to maintain the programmed vehicle height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation > Page 957 Suspension Mode Switch: Service and Repair Removal WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury. 1. Turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Peel back the luggage compartment trim. 1 Remove the pushpins. 2 Peel back the luggage compartment trim. 4. Remove the air suspension switch. 1 From behind the quarter panel reinforcement, depress the clips. 2 Remove the air suspension switch. 5. Disconnect the electrical connector. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 968 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 974 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 978 Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 979 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 983 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 984 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Loosen the digital Transmission Range (TR) bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 985 7. Tighten the bolts. 8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR sensor electrical connector. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 986 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 990 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 999 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 1000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 1001 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1002 Power Window Switch: Description and Operation PRINCIPLES OF OPERATION The driver power window one touch down operation is controlled by the Driver Door Module (DDM), if equipped with remote keyless entry, or the one touch down module if not equipped with remote keyless entry. The one touch down operation is requested of the module by momentarily pressing the driver window down switch for 32 ms to 480 ms. The module uses the initial voltage input from the down switch to begin one touch down operation. If the voltage input was less than 480 ms, the module will maintain the voltage supply to the motor down circuit. Circuit breaker 14 (20 A) supplies the power to the module for this operation. The module will maintain the operation until: seven seconds expire. - the module detects motor stalled by monitoring the current draw. - a voltage input is received by the module on either the up or down switch circuits. The ground for one touch down operation does not pass through the module. The ground is supplied through the driver window switch as with normal operation. If the module continues to detect voltage on the down circuit for more than 480 ms after initial activation, the module will not affect operation. The down circuit through the module is a direct connection to the motor in its normal state. This allows the driver window switch to control the motor for normal operation. The passenger window motors are hardwired directly to the window regulator control switches. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch Power Window Switch: Testing and Inspection LR Window Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 1005 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 1006 Power Window Switch: Testing and Inspection Master Power Window Switch Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 1007 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 1008 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 1009 Power Window Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 1010 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 1011 Power Window Switch: Testing and Inspection Right Rear Power Window Switch Component Testing Procedure Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1012 Power Window Switch: Service and Repair REMOVAL 1. Remove the switch bezel. 2. Remove the screws. 3. Disconnect the connector. 4. Remove the master window regulator control switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1017 Windshield Washer Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1018 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1019 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1020 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1021 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1025 Wiper Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1026 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1027 Wiper Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1028 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1029 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1035 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1036 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1037 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1038 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1039 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1040 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1041 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1042 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1043 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1044 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1045 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1046 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1047 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1048 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1049 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1050 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1051 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1052 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1053 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1054 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1055 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1056 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1057 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1058 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1059 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1060 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1061 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1062 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1063 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1064 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1065 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1066 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1067 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1068 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1069 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1070 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1071 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1072 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1073 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1074 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1075 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1076 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1077 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1078 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1079 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1080 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1081 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1082 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1083 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1084 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1085 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1086 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1087 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1088 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1089 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1090 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1091 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1092 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1093 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1094 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1095 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Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1101 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1102 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1103 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1104 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1105 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1106 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1107 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1108 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1109 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1110 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1111 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1112 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1113 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1114 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1115 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1116 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1117 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1118 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1119 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1120 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1121 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1122 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1123 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1124 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1125 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1126 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1127 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1128 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1129 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1130 Alignment: Specifications NOTE: All specifications are given for a vehicle at curb load. CAMBER: Nominal ............................................................................................................................................... ..................................................................... -0.50° Tolerance ............................................................ ..................................................................................................................................................... ±0.75° Difference/Split (Left Minus Right) Nominal ............................................................................................................................................... ................................................................ 0.00° Tolerance .................................................................. ......................................................................................................................................... ±0.75° CASTER: Nominal ............................................................................................................................................... .................................................................... +5.50° Tolerance ............................................................ ..................................................................................................................................................... ±0.75° Difference/Split (Left Minus Right) Nominal ............................................................................................................................................... ................................................................ +0.5° Tolerance .................................................................. ......................................................................................................................................... ±0.75° TOTAL TOE [a] Degree: Nominal ............................................................................................................................................... ............................................................. -0.125° Tolerance .................................................................. ......................................................................................................................................... ±0.25° CLEAR VISION [b]: Nominal ............................................................................................................................................... ....................................................................... -2.0° Tolerance ............................................................ ....................................................................................................................................................... ±3.0° RIDE HEIGHT Base Front .................................................................................................................................................... ........................ 29.6 ±12.7 mm (1.2 ±0.5 inch) Rear ........................................................................... ................................................................................................ 138.0 ±7.60 mm (5.4 ±0.3 inch) Air Suspension Front .................................................................................................................................................... ........................ 27.4 ±12.7 mm (1.1 ±0.5 inch) Rear ........................................................................... .................................................................................................. 132.4 ±7.6 mm (5.2 ±0.3 inch) With Handling package Front .................................................................................................................................................... ........................ 26.0 ±12.7 mm (1.0 ±0.5 inch) Rear ........................................................................... .................................................................................................. 132.4 ±7.6 mm (5.2 ±0.3 inch) Police/NGV Front .................................................................................................................................................... ........................ 26.4 ±12.7 mm (1.0 ±0.5 inch) Rear ........................................................................... .................................................................................................. 132.3 ±7.6 mm (5.2 ±0.3 inch) VEHICLE LEAN (Side to Side Height Difference) Front .................................................................................................................................................... ................................................ 12.7 mm (0.5 inch) Rear ..................................................................... ................................................................................................................................ 12.7 mm (0.5 inch) [a] Positive value is toe-in, negative value is toe-out. [b] Position of steering wheel spoke to horizontal. Negative value specification is counterclockwise. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1131 Alignment: Description and Operation Camber and caster are adjusted by means of two adjustment cams located on each upper control arm. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. 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 Caster is the deviation from vertical of an imaginary line drawn through the ball joints 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. TOE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1132 Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. RIDE HEIGHT Front Ride Height Measurement Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1133 Rear Ride Height Measurement On vehicles equipped with an air suspension system, the vehicle ride height can only be measured accurately after the accurate trim test has been executed using a NGS tester. Wheel Track WHEEL TRACK Refer to image provided. DOGTRACKING Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1134 Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. 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. SHIMMY Shimmy, as observed 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. NIBBLE Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. POOR RETURNABILITY/STICKY STEERING Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. 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 hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road crown). 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° of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20° of turn, most of the turning effort that builds up comes from the mesh of 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 readability problem, it is important to understand the difference between wander and poor groove feel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber 1. Loosen the nuts. 2. To adjust the camber, rotate the adjustment cam. ^ To increase camber, rotate the adjustment cam clockwise. ^ To decrease camber, rotate the adjustment cam counterclockwise. 3. To adjust the caster, rotate the adjustment cam. ^ To increase the caster, rotate the adjustment cam clockwise. ^ To decrease the caster, rotate the adjustment cam counterclockwise. 4. Hold each cam and tighten the nuts. 5. Recheck the camber and caster. Follow the manufacturer's instructions. Readjust the camber and caster as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1137 Alignment: Service and Repair Toe 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings. Follow the manufacturer's instructions. 4. Loosen the nuts. ^ Clean-and lubricate the steering linkage and tie rod end threads. 5. Rotate the adjusting sleeves to obtain the correct toe setting. 6. Position the adjusting sleeve clamps within the horizontal and vertical limits shown. Tighten the nuts. 7. Recheck the toe settings. Follow the manufacturer's instructions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Fuel Rail Pressure 105 - 130 psi Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 1143 Fuel Pressure: Specifications Volume Flow ..................................................................................................................................................... ................................................................. 160 lbs/hr Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed Idle Speed Hot Idle 790-815 rpm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. On gasoline vehicles, remove the engine appearance cover. ^ Loosen the retainer. ^ Remove the cover. 2. Remove the idle air control valve inlet tube. 3. Remove the crankcase ventilation hose. 4. Loosen the clamps and remove the air cleaner outlet tube. NOTE: Gasoline shown, natural gas similar. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1151 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 REMOVAL 1. Release the metal clips. 2. Lift the cover. 3. Remove the Air Cleaner (ACL) element. INSTALLATION 1. To install,reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1160 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Typical Vent Stack Installation NOTE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1161 ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1162 Fuel Pressure Release: Service and Repair Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1163 minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1164 Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1165 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1166 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1167 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1168 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1169 Typical Vent Stack Installation NOTE ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1170 ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1171 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1172 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1173 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1174 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Open 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open as necessary. Disconnect the electrical Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1175 connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Ground Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1176 6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as stuck open. 8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The pressure should be at or near 0 kPa (0 psi). 10. Remove the fuel tank solenoid manual lock-down valve. 11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1177 12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops. 14. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 15. Perform the fuel line venting procedure. 16. Remove the Manual Override Tool from the fuel tank solenoid valve. 17. Install the fuel tank solenoid manual lock~down valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1178 18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Closed 1. Connect the Grounding Cable to the back side of NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1179 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the manual bleed valve on the Fuel Filler Neck Venting Kit. 7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1180 8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 9. Turn in the Manual Override Tool jackscrew until fuel flows. 10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure reading should be at tank pressure. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Vent the fuel tank until the fuel flow stops. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1181 13. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 14. Perform the fuel line venting procedure. 15. Remove the Manual Override Tool from the fuel tank solenoid valve. 16. Install the fuel tank solenoid manual lock-down valve. 17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order 1-3-7-2-6-5-4-8 Coil On Plug Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plugs 20 Nm Spark Plug Gap 1.32-1.42 mm Spark Plug Type AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1193 Spark Plug: Specifications Spark Plugs 20 Nm Spark Plug Gap 1.32-1.42 mm Spark Plug Type AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1194 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................................................... AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1195 Spark Plug: Description and Operation The spark plugs: ^ change a high voltage pulse into a spark which ignites the fuel and air mixture. ^ originally equipped on the vehicle have a platinum-enhanced active electrode for long life. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1196 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil. 2. Remove the spark plugs. NOTE: Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 3. Inspect the spark plugs for a gap bridged. ^ Check for deposit build-up closing the gap between electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 4. Inspect 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1197 5. Inspect for carbon fouling, identified by black, dry, fluffy carbon deposits on insulator tips, exposed shell surfaces and electrodes. This is caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 6. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 7. Inspect for pre-ignition, ^ identified by melted electrodes and possibly a damaged insulator. Metallic deposits on the insulator indicate engine damage, which may be caused by incorrect ignition timing, wrong type of fuel or the installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 8. Inspect for overheating, identified by a white or light gray insulator with small black or gray-brown spots with bluish-burnt appearance of electrodes. This can be caused by engine overheating, the wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1198 ^ Install a new spark plug. 9. Inspect for fused spot deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. 10. Adjust the spark plug gap as required. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart (Part 1 Of 2) Compression Pressure Limit Chart (Part 2 Of 2) The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1202 Compression Check: Testing and Inspection Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Pressure Limit Chart (Part 1 Of 2) Compression Pressure Limit Chart (Part 2 Of 2) Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1203 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Drive Belt: Specifications Drive Belt Tension See Note Newly Installed-Refers To The Condition Of The NEW Drive Belt Before The Engine Has Made No More Than One Revolution And Before The Belt Has Had A Chance To Stretch Or Seat Into The Pulley Grooves Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1210 Drive Belt: Diagrams Part 1 Of 2 Part 2 Of 2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1211 Drive Belt: Service and Repair Removal 1. Rotate the tensioner clockwise and remove the drive belt. Installation 1. CAUTION: Incorrect drive belt installation will cause drive belt failure. NOTE: Make sure the drive belt is correctly installed on each pulley. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. On gasoline vehicles, remove the engine appearance cover. ^ Loosen the retainer. ^ Remove the cover. 2. Remove the idle air control valve inlet tube. 3. Remove the crankcase ventilation hose. 4. Loosen the clamps and remove the air cleaner outlet tube. NOTE: Gasoline shown, natural gas similar. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1217 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Release the metal clips. 2. Lift the cover. 3. Remove the Air Cleaner (ACL) element. INSTALLATION 1. To install,reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This model is not equipped with a cabin air filter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1229 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Typical Vent Stack Installation NOTE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1230 ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1231 Fuel Pressure Release: Service and Repair Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1232 minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1233 Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1234 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1235 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1236 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1237 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1238 Typical Vent Stack Installation NOTE ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1239 ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1240 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1241 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1242 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1243 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Open 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open as necessary. Disconnect the electrical Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1244 connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Ground Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1245 6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as stuck open. 8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The pressure should be at or near 0 kPa (0 psi). 10. Remove the fuel tank solenoid manual lock-down valve. 11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1246 12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops. 14. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 15. Perform the fuel line venting procedure. 16. Remove the Manual Override Tool from the fuel tank solenoid valve. 17. Install the fuel tank solenoid manual lock~down valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1247 18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Closed 1. Connect the Grounding Cable to the back side of NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1248 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the manual bleed valve on the Fuel Filler Neck Venting Kit. 7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1249 8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 9. Turn in the Manual Override Tool jackscrew until fuel flows. 10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure reading should be at tank pressure. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Vent the fuel tank until the fuel flow stops. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1250 13. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 14. Perform the fuel line venting procedure. 15. Remove the Manual Override Tool from the fuel tank solenoid valve. 16. Install the fuel tank solenoid manual lock-down valve. 17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1260 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1261 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1267 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1268 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1269 Heater Hose: Service and Repair REMOVAL 1. Drain the radiator. 2. Remove the heater hoses from the heater core. 3. Remove the heater hoses from the engine. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation REFRIGERANT LINES NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C compressor to condenser discharge line contains high pressure refrigerant gas. It has the following features: an integral non-serviceable muffler - a fitting used to mount the A/C pressure cut-off switch. (A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system.) - a fitting used to mount a serviceable high-pressure A/C charge port valve The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a port to mount the A/C compressor pressure relief valve. The accumulator to compressor tube has a fitting used to mount the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Disconnect the A/C pressure cut-off switch wire harness connector. 4. Remove the A/C pressure cut-off switch. 5. Remove the A/C compressor to condenser discharge line nut. 6. Disconnect the A/C compressor to condenser discharge line from the A/C manifold and tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1275 7. Disconnect the A/C compressor to condenser discharge line from the A/C condenser core and remove the A/C compressor to condenser discharge line. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1276 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Condenser To Evaporator Line REMOVAL 1. Recover the refrigerant. 2. Disconnect the condenser to evaporator tube from the A/C evaporator core. 3. Disconnect the condenser to evaporator tube from the A/C condenser core and remove the condenser to evaporator tube. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Evaporator to Compressor Suction Line REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1277 3. Disconnect the A/C cycling switch wire harness connector. 4. Remove the A/C cycling switch. 5. Disconnect the evaporator to compressor suction line from the suction accumulator/drier. 6. Disconnect and remove the evaporator to compressor suction line from the A/C manifold and tube assembly. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Page 1278 Spring Lock Coupling Disconnect Tool Set Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Hose To Pump .............................................................................................................................................. ................................................. 40 Nm (30 ft. lbs.) To Gear ................................................................ ................................................................................................................................. 20 Nm (15 ft. lbs.) Return Hose To Gear ............................................................................................................................................... .................................................. 20 Nm (15 ft. lbs.) Routing Clip ......................................................................................................................................... ................................................... 8 Nm (71 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1282 Power Steering Line/Hose: Service and Repair Removal 1. Refer to the illustration provided for the hose routing and retention points. Installation 1. When connecting a fitting with a seal ring, a new seal ring must be installed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1283 ^ The special tool is used to install the return line connector seal and the pressure line connector seal. 2. Fill and leak check the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1284 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair Radiator Hose: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Raise the vehicle. 2. Drain the coolant. 3. Remove the lower radiator hose from the radiator. 4. Remove the lower radiator hoses from the oil cooler; (with engine oil cooler). 5. Lower the vehicle. 6. Remove the lower radiator hose from the degas bottle. 7. Remove the lower radiator hose from the oil filter adapter assembly and remove the lower radiator hoses from the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Page 1288 Installation 1. NOTE: Position clamps properly. Follow the removal procedure in reverse order. 2. Fill the cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Technician Safety Information Brake Fluid: Technician Safety Information SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: ^ Eye Contact - rinse eyes thoroughly with water. ^ Skin Contact - wash skin with soap and water. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Technician Safety Information > Page 1295 Brake Fluid: Vehicle Damage Warnings Use clean, fresh Ford High Performance DOT3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. These types are the only brake fluids that should be used in Ford vehicles. Do not reuse brake fluid drained or bled from the system. - Do not use brake fluid that has been stored in an open container. - Do not mix different types of brake fluid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1300 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Cooling System 15 L Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1303 Coolant: Fluid Type Specifications Coolant Type ....................................................................................................................................... ................................ Ford Premium Engine Coolant Ford Specification................................................................................................................................. .........................................................ESE-M97B44-A Note: Use Ford Premium Engine Coolant (green in color). DO NOT USE Ford Extended LIfe Engine Coolant (orange in color). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1304 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid .............................................................................................................................................. ........................................................ 13.1L (13.8 Qt) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1309 Fluid - A/T: Fluid Type Specifications Item ...................................................................................................................................................... ............................................................. Specification Motorcraft MERCON V Automatic Transmission Fluid ................................................................................................................................... MERCON V Note: MERCON V is not interchangeable at this time with the current MERCON service fluids. Check the transmission dipstick to determine the correct fluid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1310 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1311 Fluid - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, etc., is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter, transmission cooler tubes must be thoroughly flushed to remove any dirt and the oil-to-air cooler must be replaced. The oil-to-air cooler must be replaced under the following conditions: 1. Evidence of transmission assembly or fluid contamination is found due to the following transmission or converter failure modes: ^ major metallic failure ^ multiple clutches or clutch plate failures 2. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid. ^ Normal Maintenance Change fluid at 48,279 km (30,000 miles). ^ Severe Duty/Major Overhaul Change fluid at 33,795 km (21,000 miles). CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. 2. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specifications for capacity. Check the fluid level. Removal 1. If equipped deactivate the air suspension. 2. Disconnect the battery ground cable 3. Raise the vehicle on a hoist. 4. Place a drain pan under the transmission fluid pan. 5. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. ^ Replace transmission fluid pan gasket as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1312 7. Remove torque converter housing plug. 8. Remove the torque converter drain plug and drain the torque converter. ^ Rotate the crankshaft to access the drain plug. 9. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 10. Flush the fluid cooler tubes. 11. Flush the torque converter. Installation NOTE: A new torque converter drain plug must be used. 1. Install the torque converter drain plug. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1313 2. Install the torque converter housing plug. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. 3. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. 5. Install the transmission fluid pan and gasket. 1. Position transmission fluid pan gasket. 2. Position the transmission fluid pan. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1314 6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped reactivate the air suspension.. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). 10. Fill transmission to proper fluid level. ^ Use Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent fluid meeting Ford specification MERCON V(R). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Capacity Standard Axle ...................................................................................................................................... .................................................................... 1.8 - 1.9L Traction-Lok Axle ................................................................................................................................. ................................................................. 2.2 - 2.4L Traction-Lok differentials add 4 oz of friction modifier C8AZ-19B956-A on refill. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1319 Fluid - Differential: Fluid Type Specifications Standard Applications Premium Rear Axle Lubricant SAE 80W90 Specification .................................................................... ........................................................................................................................... WSP-M2C197-A Police, Taxi, Limo Applications High Performance Rear Axle Lubricant SAE 75W140 Specification ................................................... ............................................................................................................................................ WSL-M2C192-A Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1320 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1325 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1326 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1327 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1328 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity ............................................................................................................................................... ................................................ 6.24L (6.6 Qt +/- 0.1) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1331 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 NOTE: Refer to TSB# 02-1-9 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1332 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1337 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1338 Power Steering Fluid: Specifications Use Motorcraft MERCON(r) Multi-Purpose ATF, XT-2-QDX or equivalent MERCON(r) approved fluid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1339 Power Steering Fluid: Service Precautions CAUTION: Use only manufacturer recommended Power Steering Fluid or system damage may result. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1344 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1345 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1346 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1347 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ........................................................... 1.08 kg (38 oz) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1350 Refrigerant: Fluid Type Specifications Refrigerant............................................................................................................................................ ........................................................................R134a Ford Part Number ................................................................................................................................ ..................................................................... YN-19 Ford Specification ................................................................................................................................ ................................................... WSH-M17B19-A Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Oil Capacity ......................................................................................................................................... ........................................................... 222 ml (7.5 oz) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1355 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil...................................................................................................................................... ...Polyalkylene Glycol (PAG) Oil (R-134a Systems) Ford Part Number ........................................................................................................................................................... F7AZ-19589-AD (MC-YN-12C) Ford Specification ................................................................................................................................ .................................................. WSH-M1C231-B Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the Brake Pedal (BP) and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1360 Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of a new part, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the NGS instructions. 2. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 3. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Have an assistant hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1361 6. Tighten the RH rear bleeder screw. 7. Repeat Steps 3, 4, 5 and 6 for the LH rear bleeder screw. 8. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 9. Have an assistant hold firm pressure on the brake pedal. 10. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 11. Tighten the RH front disc brake caliper bleeder screw. 12. Repeat Steps 8, 9, 10 and 11 for the LH front disc brake caliper bleeder screw. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1362 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder has been primed at the bench, install it in the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1363 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2 Loosen the rear-most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1364 Brake Bleeding: Service and Repair Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the 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: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1365 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: This procedure only needs to be performed if the 4-Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been replaced or if the HCU lines have been opened. NOTE: Ford provides no information or procedures to bleed the brake system without the Rotunda New Generation Star (NGS) tester/scan tool. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1366 4. Tighten the RH rear bleeder screw, and disconnect the waste line. 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedures 1. Disconnect the battery ground cable and wait at least one minute. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedures 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Install the passenger air bag module. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 1372 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the vehicle battery connected? Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1378 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1379 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1380 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1381 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1382 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1383 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1384 Circuit Breaker: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1385 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 1395 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1398 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1399 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1400 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1401 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1402 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1403 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1404 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1405 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1406 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1407 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1408 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1409 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1410 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 1413 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1418 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1419 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1420 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1421 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1422 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1423 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1424 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1425 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1426 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1427 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1428 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1429 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1430 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > High Current Relay Center Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 1435 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 1436 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation SERVICE ENGINE SOON Your vehicle is equipped with a computer that monitors the engine's emission control system. This is commonly known as the On Board Diagnostic System (OBD II). This OBD II system protects the environment by ensuring that your vehicle continues to meet government emission standards. The OBD II system also assists the service technician in properly servicing your vehicle. The SERVICE ENGINE SOON indicator light illuminates when the ignition is first turned to the ON position to check the bulb. If it comes on after the engine is started, on of the engine's emission control systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will ususally be drivable and will not require towing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 1441 Maintenance Required Lamp/Indicator: Service and Repair Solid SERVICE ENGINE SOON light This means that the On Board Diagnostic System (OBD II) has detected a malfunction. Temporary malfunctions may cause your SERVICE ENGINE SOON light to illuminate. Examples are: 1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or water in the fuel. 3. The fuel cap may not have been properly installed and securely tightened. The temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or properly installing and securely tightening the gas cap. After three driving cycles with out these or any other temporary malfunctions present, the SERVICE ENGINE SOON light should turn off. (A driving cycle consists of a cold engine start-up followed by mixed city/highway driving.) No additional vehicle service is required. Blinking SERVICE ENGINE SOON light Engine misfire is occurring which could cause damage to your catalytic converter. You should drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced at the first available opportunity. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair NOTE : This vehicle is not equipped with an CHANGE OIL SOON or OIL CHANGE REQUIRED indicator. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Suspension Warning Indicator > Component Information > Description and Operation Suspension Warning Indicator: Description and Operation The CHECK AIR SUSPENSION warning indicator illuminates when a concern in the air suspension system is detected or when the air suspension switch is in the OFF position. During prove-out, when a concern is detected or the air suspension switch is OFF, an audible tone will sound and the CHECK AIR SUSPENSION warning indicator will flash on and off for five seconds. The CHECK AIR SUSPENSION warning indicator will then remain illuminated until the concern is corrected or the air suspension switch is switched ON. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure Technical Service Bulletin # 00S13 Date: 000701 Recall - Vehicle Jacking Procedure SAFETY RECALL 00S13 Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment II ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1457 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1458 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental vehicles are not approved for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage label, and a jack usage and stowage placard will be sent directly to owners, along with instructions on placement of the various pieces. This will be a "no charge" service and customers will be directed to follow the attached instructions for proper placement of the labels and owner guide supplement. Additional owner packages containing the above mentioned items can be ordered by calling the Recall Hotline at 1-800-325-5621. Attachment III - Technical Information OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the vehicle: ^ Tire Change Procedure Supplement. ^ Jack Operating Instructions label. ^ Jack Usage and Stowage label. ^ Jack Usage and Stowage/Tire Changing Instruction placard. The following instructions/illustrations will help locate the proper area for each of these items. TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1459 1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located in the glove compartment. See Figure 1. JACK OPERATING INSTRUCTIONS LABEL PLACEMENT NOTE: The jack may be located under the spare tire or behind the right quarter trim panel. 1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by removing the right quarter trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1460 2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2. JACK USAGE AND STOWAGE LABEL PLACEMENT NOTE: The Jack Usage and Stowage label may be located on the inner right quarter panel or the underside of the spare tire cover. 1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and Stowage label directly over the original label as illustrated. See Figure 3. JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1461 1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing Instruction placard on top of the spare tire as illustrated. See Figure 4. 2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1462 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1463 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure Technical Service Bulletin # 00S13 Date: 000701 Recall - Vehicle Jacking Procedure SAFETY RECALL 00S13 Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment II ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1469 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1470 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental vehicles are not approved for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage label, and a jack usage and stowage placard will be sent directly to owners, along with instructions on placement of the various pieces. This will be a "no charge" service and customers will be directed to follow the attached instructions for proper placement of the labels and owner guide supplement. Additional owner packages containing the above mentioned items can be ordered by calling the Recall Hotline at 1-800-325-5621. Attachment III - Technical Information OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the vehicle: ^ Tire Change Procedure Supplement. ^ Jack Operating Instructions label. ^ Jack Usage and Stowage label. ^ Jack Usage and Stowage/Tire Changing Instruction placard. The following instructions/illustrations will help locate the proper area for each of these items. TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1471 1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located in the glove compartment. See Figure 1. JACK OPERATING INSTRUCTIONS LABEL PLACEMENT NOTE: The jack may be located under the spare tire or behind the right quarter trim panel. 1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by removing the right quarter trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1472 2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2. JACK USAGE AND STOWAGE LABEL PLACEMENT NOTE: The Jack Usage and Stowage label may be located on the inner right quarter panel or the underside of the spare tire cover. 1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and Stowage label directly over the original label as illustrated. See Figure 3. JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1473 1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing Instruction placard on top of the spare tire as illustrated. See Figure 4. 2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1474 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1475 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1476 Vehicle Lifting: Description and Operation JACKING WARNING ^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. CAUTION ^ 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. Refer to the Owner Guide when using the jack supplied with the vehicle. ^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer or differential housing. Severe damage to the vehicle could result. ^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to the bumper covers will occur. Lift the vehicle using the Jacking Points procedure. Jacking Points Push the air suspension service switch to the OFF position. To lift the front or either side of the front end, position the floor jack or the hoist under the front frame lift points. To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift points. LIFTING WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION ^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar, rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator. Damage to the suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1477 ^ Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. Lift the vehicle using the Lifting Points procedure. Lifting Points-Drive-On Lift CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference. Check for interference between the upright flanges of the hoist rails and the underbody. If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to provide clearance. Lifting Points-Two Post Lift CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1478 Lifting Points-Single-Post Hoist CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1479 Vehicle Lifting: Service and Repair JACKING WARNING ^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. CAUTION ^ 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. Refer to the Owner Guide when using the jack supplied with the vehicle. ^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer or differential housing. Severe damage to the vehicle could result. ^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to the bumper covers will occur. Lift the vehicle using the Jacking Points procedure. Jacking Points Push the air suspension service switch to the OFF position. To lift the front or either side of the front end, position the floor jack or the hoist under the front frame lift points. To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift points. LIFTING WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION ^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar, rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator. Damage to the suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1480 ^ Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. Lift the vehicle using the Lifting Points procedure. Lifting Points-Drive-On Lift CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference. Check for interference between the upright flanges of the hoist rails and the underbody. If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to provide clearance. Lifting Points-Two Post Lift CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1481 Lifting Points-Single-Post Hoist CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications Wheel Size .......................................................................................................................................... ...................................................................... 16 x 4.5 Bolt Circle ....................................................... ...................................................................................................................................... 114.3 mm (4.5 inch) Lugs ..................................................................................................................................... ................................................................................................. 5 Offset .............................................. .............................................................................................................................................................. ............ 9 (inset) Tire Usage ................................................................................................................ ............................................................................... T145/80D16 105M Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Wheels: Customer Interest Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Wheels: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 1503 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis Wheels: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis Article No. 01-1-14 01/22/01 ^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) ^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) FORD: 1999-2001 CROWN VICTORIA MERCURY: 1999-2001 GRAND MARQUIS ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph) which may be related to driveshaft, axle, wheels, or their components. ACTION Identify the causal component for the vibration and balance or replace as necessary to eliminate the vibration. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 1508 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 1509 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 1510 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 1511 For Dealerships with An Electronic Vibration Analyzer Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration conditions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 1512 Driveline Vibration Data Sheet OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1517 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1518 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1519 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1520 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1521 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1522 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1523 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1524 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1525 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1526 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1527 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1528 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1529 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1530 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1531 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1532 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1533 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1534 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1535 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1536 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1537 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1538 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1539 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1540 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1541 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1542 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1543 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1544 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1545 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1546 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1547 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1548 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1549 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1550 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1551 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1552 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1553 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1554 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1555 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1556 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1557 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1558 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1559 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1560 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1561 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1562 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1563 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1564 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1565 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1566 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1567 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1568 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1569 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1570 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1571 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1572 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1573 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1574 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1575 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1576 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1577 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1578 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1579 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1580 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1581 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1582 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1583 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1584 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1585 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1586 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1587 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1588 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1589 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1590 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1591 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1592 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1593 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1594 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1595 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1596 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1597 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1598 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1599 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1600 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1601 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1602 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1603 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1604 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1605 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1606 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1607 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1608 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1609 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1610 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1611 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 1617 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis Wheels: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis Article No. 01-1-14 01/22/01 ^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) ^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) FORD: 1999-2001 CROWN VICTORIA MERCURY: 1999-2001 GRAND MARQUIS ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph) which may be related to driveshaft, axle, wheels, or their components. ACTION Identify the causal component for the vibration and balance or replace as necessary to eliminate the vibration. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 1622 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 1623 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 1624 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 1625 For Dealerships with An Electronic Vibration Analyzer Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration conditions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 1626 Driveline Vibration Data Sheet OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1631 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1632 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1633 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1634 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1635 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1636 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1637 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1638 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1639 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1640 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1641 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1642 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1643 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1644 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1645 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1646 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1647 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1648 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1649 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1650 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1651 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1652 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1653 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1654 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1655 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1656 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1657 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1658 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1659 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1660 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1661 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1662 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1663 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1664 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1665 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1666 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1667 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1668 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1669 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1670 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1671 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1672 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1673 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1674 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1675 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1676 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1677 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1678 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1679 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1680 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1681 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1682 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1683 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1684 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1685 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1686 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1687 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1688 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1689 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1690 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1691 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1692 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1693 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1694 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1695 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1696 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1697 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1698 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1699 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1700 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1701 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1702 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1703 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1704 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1705 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1706 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1707 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1708 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1709 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1710 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1711 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1712 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1713 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1714 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1715 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1716 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1717 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1718 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1719 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1720 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1721 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1722 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1723 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1724 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1725 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1726 Wheels: Specifications Bolt Circle ............................................................................................................................................ ................................................. 114.3 mm (4.5 inch) Balance Weights, Max. Per Wheel ............................................................................................................................................ ...................................................... 140 g (5.0 oz.) Per Side ................................................................ ......................................................................................................................................... 70 g (2.5 oz.) Lugs ..................................................................................................................................................... ................................................................................. 5 Offset Steel .................................................................................................................................................... .......................................................................... 11 Aluminum ............................................................. ......................................................................................................................................................... 4.5 Runout, Max Radial .................................................................................................................................................. ............................................. 0.64 mm (0.025 inch) Lateral ................................................................. ............................................................................................................................. 0.89 mm (0.035 inch) Size ...................................................................................................................................................... ......................................................................... 16 x 7 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1727 Wheels: Testing and Inspection TIRE AND WHEEL RUNOUT Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor. Before checking runout, and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm the tires. The extent of the runout is measured with the radial runout gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures. TIRE RUNOUT Measure radial and lateral tire runout at the positions shown in the illustration. Runout should not exceed specifications. WHEEL RUNOUT Measure radial and lateral wheel runout at the positions shown in the illustration. Runout should not exceed specifications. Note that the tire has been removed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks Wheels: Service and Repair Leaks NOTE: Wheel repairs that use welding or peening are not approved. An inner tube is not an acceptable repair for leaking wheels or tires. If the air pressure in a tire mounted on an aluminum wheel is found to be low, perform the following procedure before considering wheel replacement. 1. Remove the tire and wheel assembly, and inspect the wheel for structural damage. If none exists, go to Step 2. If the wheel is damaged, install new. 2. With the tire mounted on the wheel, locate the air leak using a water bath or equivalent method, and mark the location. Check the complete wheel for possible additional leaks. When leaks are marked, dismount the tire marking valve location on the tire for correct indexing. 3. On the tire side of the wheel, thoroughly clean the leaking area with an appropriate cleaner (Professional Choke and Linkage Cleaner E8AZ-19A501-AA or equivalent meeting Ford specification ESR-M14P10-A) or use sandpaper of approximately 80-grit to remove all contamination. Using the sandpaper, score the surface of the leaking area to improve adhesion of the sealer. If the valve stem is close to the area, remove it. 4. Use a clean cloth to remove all cleaner or sanding dust. 5. NOTE: Do not use a torch containing oxyacetylene. Heat the prepared area with a Heat Gun or a propane torch until Aluminum Wheel Repair Compound E7AZ-19554-A or equivalent meeting Ford specification ESA-M4G280-A flows. Apply the hot melt material over the prepared area using a liberal flow and wiping action. Repair is most effective when heat is applied to the brake side of the rim, and the sealer is melted by heat in the metal. 6. Apply only enough heat to melt the sealer, then remove the heat source. After repairing the leak, allow the wheel to cool until it can be handled safety. 7. CAUTION: Use caution when mounting the tire so as not to damage the sealer. Index and assemble the tire and wheel. Inflate the tire to the recommended pressure as indicated on the tire pressure decal. 8. Repeat Step 2 to verify repair. 9. When the repair is completed, balance the assembly and install it on the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 1730 Wheels: Service and Repair Replacement Removal 1. Loosen the lug nuts. 1 Remove the wheel cover or ornament. 2 CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Loosen, but do not remove the lug nuts. 2. CAUTION: Never use the differential housing as a lift point. Raise the vehicle until the tire clears the floor. 3. CAUTION: Do not use heat to loosen a frozen wheel because heat can shorten the life of the wheel and damage the wheel bearings. If the wheel cannot be removed by hand, use a wheel puller to remove the frozen wheel. Remove the wheel and tire from the vehicle. ^ Remove the lug nuts. ^ Remove the wheel and tire. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, resulting in loss of control. Position the wheel and tire on the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 1731 2. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts to specification in a star-pattern sequence. 3. Install the wheel cover or ornament. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1736 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1737 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1738 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1739 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1740 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1741 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1742 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1743 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1744 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1745 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1746 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1747 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1748 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1749 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1750 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1751 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1752 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1753 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1754 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1755 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1756 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1757 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1758 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1759 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1760 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1761 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1762 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1763 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1764 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1765 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1766 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1767 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1768 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1769 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1770 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1771 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1772 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1773 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1774 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1775 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1776 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1777 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1778 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1779 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1780 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1781 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1782 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1783 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1784 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1785 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1786 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1787 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1788 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1789 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1790 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1791 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1792 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1793 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1794 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1795 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1796 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1797 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1798 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1799 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1800 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1801 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1802 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1803 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1804 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1805 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1806 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1807 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1808 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1809 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1810 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1811 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1812 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1813 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1814 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1815 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1816 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1817 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1818 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1819 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1820 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1821 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1822 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1823 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1824 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1825 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1826 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1827 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1828 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1829 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1830 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1831 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1832 Wheel Bearing: Testing and Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, install a new wheel hub. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1833 Wheel Bearing: Service and Repair FRONT WHEEL HUB Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. Remove and discard the front hub cap grease seal. 5. CAUTION: The front axle wheel hub retainer must never be reused. If the retainer is reused, it can back off resulting in loss of the front wheel and or damage to the wheel hub and bearing assembly. Remove the front axle wheel hub retainer. Discard the retainer. 6. CAUTION: When removing the wheel hub and bearing, use caution not to damage the ABS sensor lead or the ABS sensor ring. NOTE: The wheel hub and bearing assembly is a slip fit design and should not require a puller to remove. Remove the wheel hub and bearing assembly. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1834 1. CAUTION: When installing the wheel hub and bearing, use extreme caution not to damage the ABS sensor lead or the ABS sensor ring. Install the wheel hub and bearing assembly. 2. Install a new front axle wheel hub retainer. 3. Install a new front hub cap grease seal. 4. Install the brake disc. 5. Install the wheel and tire assembly. 6. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Wheel Hub Retainer ........................................................................................................................................................... 300 Nm (221 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts to 115-142 Nm (85-105 ft. lbs.) in a star-pattern sequence. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Special Tools Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. CAUTION: When removing and installing the wheel studs, use extreme caution not to damage the ABS sensor lead or the ABS sensor ring. Using the special tool, press the wheel stud out of the wheel hub and bearing flange. Installation 1. CAUTION: When removing and installing the wheel studs, use extreme caution not to damage the ABS sensor lead or the ABS sensor ring. Position the wheel stud. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1844 2. Install the wheel stud. 1 Install four washers onto the wheel stud. 2 Install reversed wheel nut. Tighten the wheel nut until the wheel stud seats fully onto the wheel hub and bearing flange. 3. Remove the wheel nut and washers. 4. Install the brake disc. 5. Install the wheel and tire assembly. 6. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1845 Wheel Fastener: Service and Repair Rear Special Tools Removal Special Tools 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off (If equipped). 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. Remove rear brake disc. 5. Using the special tool, press the lug bolt from its seat and discard. Installation CAUTION: Never use air tools to install lug bolts. The serrations can be stripped from the stud. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1846 1. Insert a new lug bolt in the hole in the axle flange, making sure serrations are aligned with those in the flange. 2. Place four flat washers over the outside end of the lug bolt, and thread a standard lug nut with the flat side against the washers. 3. Tighten the lug nut until the lug bolt head seats against the back side of the axle flange. 4. Remove the lug nut and washers. 5. Install the rear brake disc. 6. Install the wheel and tire assembly. 7. Lower the vehicle. 8. Turn the air suspension service switch on (If equipped). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 1847 Wheel Fastener: Tools and Equipment Special Tool Special Tool Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure Technical Service Bulletin # 00S13 Date: 000701 Recall - Vehicle Jacking Procedure SAFETY RECALL 00S13 Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment II ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1856 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1857 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental vehicles are not approved for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage label, and a jack usage and stowage placard will be sent directly to owners, along with instructions on placement of the various pieces. This will be a "no charge" service and customers will be directed to follow the attached instructions for proper placement of the labels and owner guide supplement. Additional owner packages containing the above mentioned items can be ordered by calling the Recall Hotline at 1-800-325-5621. Attachment III - Technical Information OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the vehicle: ^ Tire Change Procedure Supplement. ^ Jack Operating Instructions label. ^ Jack Usage and Stowage label. ^ Jack Usage and Stowage/Tire Changing Instruction placard. The following instructions/illustrations will help locate the proper area for each of these items. TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1858 1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located in the glove compartment. See Figure 1. JACK OPERATING INSTRUCTIONS LABEL PLACEMENT NOTE: The jack may be located under the spare tire or behind the right quarter trim panel. 1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by removing the right quarter trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1859 2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2. JACK USAGE AND STOWAGE LABEL PLACEMENT NOTE: The Jack Usage and Stowage label may be located on the inner right quarter panel or the underside of the spare tire cover. 1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and Stowage label directly over the original label as illustrated. See Figure 3. JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1860 1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing Instruction placard on top of the spare tire as illustrated. See Figure 4. 2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1861 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1862 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure Technical Service Bulletin # 00S13 Date: 000701 Recall - Vehicle Jacking Procedure SAFETY RECALL 00S13 Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment II ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1868 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1869 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental vehicles are not approved for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage label, and a jack usage and stowage placard will be sent directly to owners, along with instructions on placement of the various pieces. This will be a "no charge" service and customers will be directed to follow the attached instructions for proper placement of the labels and owner guide supplement. Additional owner packages containing the above mentioned items can be ordered by calling the Recall Hotline at 1-800-325-5621. Attachment III - Technical Information OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the vehicle: ^ Tire Change Procedure Supplement. ^ Jack Operating Instructions label. ^ Jack Usage and Stowage label. ^ Jack Usage and Stowage/Tire Changing Instruction placard. The following instructions/illustrations will help locate the proper area for each of these items. TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1870 1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located in the glove compartment. See Figure 1. JACK OPERATING INSTRUCTIONS LABEL PLACEMENT NOTE: The jack may be located under the spare tire or behind the right quarter trim panel. 1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by removing the right quarter trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1871 2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2. JACK USAGE AND STOWAGE LABEL PLACEMENT NOTE: The Jack Usage and Stowage label may be located on the inner right quarter panel or the underside of the spare tire cover. 1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and Stowage label directly over the original label as illustrated. See Figure 3. JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1872 1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing Instruction placard on top of the spare tire as illustrated. See Figure 4. 2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1873 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1874 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1875 Vehicle Lifting: Description and Operation JACKING WARNING ^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. CAUTION ^ 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. Refer to the Owner Guide when using the jack supplied with the vehicle. ^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer or differential housing. Severe damage to the vehicle could result. ^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to the bumper covers will occur. Lift the vehicle using the Jacking Points procedure. Jacking Points Push the air suspension service switch to the OFF position. To lift the front or either side of the front end, position the floor jack or the hoist under the front frame lift points. To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift points. LIFTING WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION ^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar, rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator. Damage to the suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1876 ^ Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. Lift the vehicle using the Lifting Points procedure. Lifting Points-Drive-On Lift CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference. Check for interference between the upright flanges of the hoist rails and the underbody. If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to provide clearance. Lifting Points-Two Post Lift CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1877 Lifting Points-Single-Post Hoist CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1878 Vehicle Lifting: Service and Repair JACKING WARNING ^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. CAUTION ^ 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. Refer to the Owner Guide when using the jack supplied with the vehicle. ^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer or differential housing. Severe damage to the vehicle could result. ^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to the bumper covers will occur. Lift the vehicle using the Jacking Points procedure. Jacking Points Push the air suspension service switch to the OFF position. To lift the front or either side of the front end, position the floor jack or the hoist under the front frame lift points. To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift points. LIFTING WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION ^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar, rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator. Damage to the suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1879 ^ Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. Lift the vehicle using the Lifting Points procedure. Lifting Points-Drive-On Lift CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference. Check for interference between the upright flanges of the hoist rails and the underbody. If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to provide clearance. Lifting Points-Two Post Lift CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1880 Lifting Points-Single-Post Hoist CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart (Part 1 Of 2) Compression Pressure Limit Chart (Part 2 Of 2) The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1886 Compression Check: Testing and Inspection Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Pressure Limit Chart (Part 1 Of 2) Compression Pressure Limit Chart (Part 2 Of 2) Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1887 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Bolts 8-12 Nm (71.4-107.1 in.lb) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications TORQUE SPECIFICATIONS Camshaft Sprocket Bolt ........................................................................................................................................................ 110-130 Nm (81-95 Ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Lobe Lift-Exhaust LH 6.59579 mm RH 6.58551 mm Lobe Lift-Intake 6.58077 mm Lobe Lift-Allowable Lobe Lift Loss 0 mm Theoretical Valve Lift @ Zero Lash-Intake 0.472 in Theoretical Valve Lift @ Zero Lash-Exhaust 0.472 in End Play .027-.190 mm End Play-Service Limit .0075 in Journal To Bearing Clearance .00098-.003 in Tighten Camshaft Bearing Caps Bolts To 8-12Nm (72-107lb/in) When Measuring Journal Clearance. Journal To Bearing Clearance(Service Limit) .076 mm Tighten Camshaft Bearing Caps Bolts To 8-12Nm (72-107lb/in) When Measuring Journal Clearance. Journal Diameter(ALL) (1.060-1.061) in Journal Diameter-Bearing Inside Diameter (1.0625-1.063) in Camshaft Journal Runout 0.09 mm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1898 Camshaft: Testing and Inspection For further information regarding this component, please refer to Engine; Service and Repair; General Procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1899 Camshaft: Service and Repair Removal 1. Remove the valve cover. 2. Remove the timing chain. 3. CAUTION: At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur. Remove the camshaft roller followers. 4. Remove the camshaft sprocket 1 Remove the bolt. 2 Remove the camshaft sprocket. 5. Remove the thirteen camshaft bearing cap bolts. 6. Remove the camshaft bearing cap ladders. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1900 7. Remove the camshaft from the cylinder head. Installation 1. Lubricate the camshaft journals. ^ Use Ford Super premium SAE 5W30 Motor oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 2. Install the camshaft onto the cylinder head. 3. Lubricate the camshaft bearing cap ladders. ^ Use Ford Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2053-6. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1901 4. Install the camshaft bearing caps and loosely install the bolts. 5. Tighten the bolts in the sequence shown. 6. Install the camshaft sprocket spacer. 1 Position the camshaft sprocket and sprocket spacer. 2 Install the bolt. 7. Install the roller follower. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1902 8. Install the timing chains. 9. Install the valve cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1903 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Lash Adjuster-Diameter (STD) (0.629-0.63) in Lash Adjuster-Clearance To Bore (0.00071-0.00272) in Lash Adjuster-Service Limit (0.00063) in Lash Adjuster-Hydraulic Leakdown Rate 5-25 sec Tighten Camshaft Bearing Cap Bolts To 8-12Nm(72-107Lb/in) When Measuring Journal Clearance Lash Adjuster-Collapsed Adjuster gap-Desired (0.0177-0.0335) in Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 1907 Lifter / Lash Adjuster: Testing and Inspection For further information regarding this component, please refer to Engine; Service and Repair; General Procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 1908 Lifter / Lash Adjuster: Service and Repair HYDRAULIC LASH ADJUSTERS Removal 1. Remove the camshaft roller followers. 2. Remove the valve tappets. Installation 1. Install the valve tappets. 2. Install the camshaft roller followers. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm-Ratio 1.75 : 1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1912 Rocker Arm Assembly: Service and Repair Special Tools ROLLER FOLLOWERS Removal 1. Remove the valve cover. 2. Position the piston of the cylinder being repaired at the bottom of the stroke. 3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1913 4. Use the Valve Spring Compressor to compress the valve springs and remove the cam roller followers. Installation 1. Use the (A) Valve Spring Compressor to compress the (B) valve spring and install the (C) camshaft roller followers. 2. Remove the Valve Spring Spacer. 3. Install the valve cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearings Connecting Rod Bearings Clearance to Crankshaft Desired 0.024-0.066 mm Allowable 0.026-0.064 mm Bearing Wall Thickness Std. 1.921-1.927 mm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt Connecting Rod: Specifications Connecting Rod Cap Bolts Stage 1 40-45 Nm (30-33 ft.lb) Stage 2 Rotate 90°-120° Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 1922 Connecting Rod: Specifications Connecting Rod-Piston Pin Bore Dianeter 22.012-22.024 mm Connecting Rod -To Piston Clearance 3.10-4.00 mm Connecting Rod-Crankshaft Bearing Bore 56.866-56.886 mm Connecting Rod(Center To Center)Length 5.93 in Alignment-Bore to Bore +/-0.05 mm >Pin Bore And Crank Bearing Bore Must Be Parallel And In Same Vertical Plane Within The Specified Total Difference When Measured At The Ends Of A 203mm (8.12in) Bar, 105mm (4.06in) On Each Side Of Rod Centerline,-Twist mm(inch). Alignment-Bore To Bore-Max Diff +/-0.038 mm Side Clearance-Assembled To Crank-Standard 0.0006-0.0117 in Side Clearance-Assembled To Crank-Service Limit (MAX) 0.02 in Connecting Rod Bolts Stage 1 30-33 ft.lb Stage 2 Rotate 90-120 Degrees Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 1923 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1924 Connecting Rod: Testing and Inspection For further information regarding this component, please refer to Engine; Service and Repair; General Procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Cylinder Block Drain Plug 16-24 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Stage 1 66 ft.lb Stage 2 Loosen 360 Degrees Stage 3 35-39 ft.lb Stage 4 Rotate 85-90 Degrees Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Jack Screws Stage 1 5 Nm (44.6 in.lb) Stage 2 9-11 Nm (80-97 in.lb) Main Bearing Cap Bolts Stage 1 10 Nm (89.2 in.lb) Stage 2 19-23 Nm (14-17 ft.lb) Main Bearing Clearance to Crankshaft - Desired 0.024-0.066 mm Clearance to Crankshaft - Allowable 0.024-0.066 mm Bearing Wall Thickness - (Std.) 1.921-1.927 mm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1934 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Journal Diameter 2.65-2.657 in Connecting Rod Journal-Diameter 2.087-2.867 in Crankshaft Main Bearing Journal Taper 0.003 in Crankshaft Main Bearing Journal Runout 0.002 in Crankshaft Connecting Rod Journal Taper 0.0005 in Crankshaft End Play 0.129-0.301 in Crankshaft Runout To Rear Face Of Block (MAX) 0.002 in Connecting Rod Clearance To Crankshaft-Desired 0.024-0.066 mm Connecting Rod Clearance To Crankshaft-Allowable 0.024-0.066 mm Connecting Rod Bearing Wall Thickness (STD) 1.921-1.927 mm Main Bearing Journal To Crankshaft-Desired 0.024-0.066 mm Main Bearing Journal To Crankshaft-Allowable 0.024-0.066 mm Main Bearing Wall Thickness(STD) 1.921-1.927 mm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1938 Crankshaft: Testing and Inspection For further information regarding this component, please refer to Engine; Service and Repair; General Procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1939 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications Block Heater Screw 14-16 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1943 Engine Block Heater: Service and Repair Removal CAUTION: Do not mix Standard (green) Coolant with Extended Life Coolant (orange). 1. Drain the engine cooling system. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Disconnect the (A) block heater wiring from the (B) block heater. 4. Remove the block heater. 1 CAUTION: Do not loosen the screw more than necessary for removal. Loosen the screw. 2 Twist and slide the block heater to release the retainer clip and remove. Discard the retainer clip. Installation 1. NOTE: To ease installation, coat the block heater seal and the cylinder block hole with Motorcraft Premium Long Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1944 Lower the vehicle. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair Special Tools CORE PLUG REPLACEMENT 1. Use a slide hammer or tools suitable to remove the cylinder block core plug. 2. Inspect the cylinder block plug bore for any damage that would interfere with the proper sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug. 3. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug. Coat the cylinder block core plug and bore lightly with Threadlock(R) 262 E2FZ-19554-B or equivalent meeting Ford specification WSK-M2G351-A6 and install the cylinder block core plug. Cup-Type 1. CAUTION: Use care during this procedure so as not to disturb or distort the cup sealing surface. CAUTION: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore. Use a tooling suitable to seat the cup type cylinder block core plug. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair > Page 1948 Expansion-Type 1. CAUTION: Do not contact the crown when installing an expansion type cylinder block core plug.This could expand the plug before seating and result in leakage. Use tooling suitable to seat the expansion type cylinder block core plug. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair > Page 1949 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt Stage 1 66 ft.lb Stage 2 Loosen 360 Degrees Stage 3 35-39 ft.lb Stage 4 Rotate 85-90 Degrees Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1953 Harmonic Balancer - Crankshaft Pulley: Service and Repair Special Tools Removal 1. Remove the engine cooling fan and fan shroud. 2. Remove the drive belt. 3. Remove the crankshaft pulley bolt. 4. Use the Crankshaft Damper Remover to remove the crankshaft pulley. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1954 1. NOTE: The crankshaft pulley must be installed within four minutes after applying the silicone. Apply silicone to the woodruff key slot on the crankshaft pulley. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4. 2. Use the Crankshaft Damper Replacer to install the crankshaft pulley. 3. Install the bolt and washer. Tighten the bolt in four steps. ^ Step 1: Tighten to 90 Nm (66 ft. lbs.). ^ Step 2: Loosen the bolt. ^ Step 3: Tighten to 47-53 Nm (34-39 ft. lbs.). ^ Step 4: Tighten an additional 85-90 degrees. 4. Install the drive belt. 5. Install the engine cooling fan and the fan shroud. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston To Bore Clearance (@ 43mm From Top) With Coating -0.005- +0.025 mm Pin Bore Diameter 10:1 Engines 21.9985-22.0025 mm 9:1 Engines 22.0065-22.0110 mm Ring Groove Width-Compression (Top) 10:1 Engines 1.23-1.25 mm 9:1 Engines 1.52-1.54 mm Ring Groove Width-Compression (Bottom) 10:1 Engines 1.52-1.54 mm 9:1 Engines 1.52-1.54 mm Ring Groove Width-Oil Ring 10:1 Engines 3.03-3.055 mm 9:1 Engines 3.03-3.055 mm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1958 Piston: Testing and Inspection For further information regarding this component, please refer to Engine; Service and Repair; General Procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1959 Piston: Service and Repair For further information regarding this component, please refer to Engine; Service and Repair; Disassembly and Assembly of Subassemblies. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pin-Length 10:1 Engines 61.601-62.030 mm 9:1 Engines 61.870-62.120 mm Piston Pin-Diameter 10:1 Engines 22.0010-22.0030 mm 9:1 Engines 21.995-21.997 mm PIn To Piston Clearance 10:1 Engines 0.0045 Interference To 0.0015 Clearance mm 9:1 Engines 0.0095-0.016 mm Pin To Rod Clearance 10:1 Engines 0.009-0.0023 mm 9:1 Engines Fixed Pin Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring To Groove Clearance Refer To Note On 10:1 Engines: Upper Compression Ring 0.030-0.070mm. Lower Compression Ring 0.020-0.060mm. On 9:1 Engines: Upper Compression Rings 0.020-0.060mm. Lower Compression Ring 0.020-0.060mm. Piston Rings-Ring Gap-Compression (Top) 0.13-0.028 mm Piston Rings-Ring Gap-Compression (Top) 0.15-0.30 mm Ring Gap - Oil Ring (Steel Rail) 0.15-0.65 mm Oil Ring-Side Clearance 0.027-0.196 mm Piston Ring-Ring Gap-Compression-(Bottom) 0.30-0.55 mm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1966 Piston Ring: Testing and Inspection For further information regarding this component, please refer to Engine; Service and Repair; General Procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1975 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Typical Vent Stack Installation NOTE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1976 ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1977 Fuel Pressure Release: Service and Repair Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1978 minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1979 Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1980 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1981 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1982 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1983 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1984 Typical Vent Stack Installation NOTE ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1985 ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1986 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1987 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1988 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1989 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Open 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open as necessary. Disconnect the electrical Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1990 connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Ground Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1991 6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as stuck open. 8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The pressure should be at or near 0 kPa (0 psi). 10. Remove the fuel tank solenoid manual lock-down valve. 11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1992 12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops. 14. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 15. Perform the fuel line venting procedure. 16. Remove the Manual Override Tool from the fuel tank solenoid valve. 17. Install the fuel tank solenoid manual lock~down valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1993 18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Closed 1. Connect the Grounding Cable to the back side of NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1994 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the manual bleed valve on the Fuel Filler Neck Venting Kit. 7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1995 8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 9. Turn in the Manual Override Tool jackscrew until fuel flows. 10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure reading should be at tank pressure. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Vent the fuel tank until the fuel flow stops. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1996 13. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 14. Perform the fuel line venting procedure. 15. Remove the Manual Override Tool from the fuel tank solenoid valve. 16. Install the fuel tank solenoid manual lock-down valve. 17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm-Ratio 1.75 : 1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2000 Rocker Arm Assembly: Service and Repair Special Tools ROLLER FOLLOWERS Removal 1. Remove the valve cover. 2. Position the piston of the cylinder being repaired at the bottom of the stroke. 3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2001 4. Use the Valve Spring Compressor to compress the valve springs and remove the cam roller followers. Installation 1. Use the (A) Valve Spring Compressor to compress the (B) valve spring and install the (C) camshaft roller followers. 2. Remove the Valve Spring Spacer. 3. Install the valve cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve Covers-Bolts Left 71-106 in.lb Right 71-106 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side Valve Cover: Service and Repair Right Side Removal 1. Raise the vehicle. 2. Disconnect the Crankshaft Position (CKP) Sensor electrical connector. 3. Disconnect the A/C compressor electrical connector. 4. Lower the vehicle. 5. Remove the evaporator case. See: Heating and Air Conditioning/Evaporator Case/Service and Repair 6. Disconnect the A/C cycling switch connector. 7. Disconnect the fuel lines. 8. Disconnect the ignition coils electrical connectors. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2007 9. Disconnect the fuel injector electrical connectors. 10. Remove the positive crankcase ventilation tube and position out of the way. 11. Disconnect the electrical connector. 12. Remove the Evaporative Emission (EVAP) Canister Purge Valve. 13. Reposition the hold-down clamp and remove the hose from the bypass tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2008 14. NOTE: The valve cover harness retaining studs positions 2, and 3 retain the fuel charging wiring. Disconnect the harness from the valve cover and position out of the way. 15. Disconnect the heater hoses from the heater core and position aside. 16. Remove the studs, the bolts and the valve cover. Installation 1. Follow the removal procedure in reverse order. Apply sealant in the locations shown; use Silicone Gasket and Sealant F7AZ-M54-EA or equivalent meeting Ford specification WSK-M2G343-A4. 2. Tighten in the sequence shown. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2009 Valve Cover: Service and Repair Left Side Removal 1. Raise and support the vehicle. 2. Disconnect the oil pressure sensor electrical connector. 3. Lower the vehicle. 4. Remove the brake booster assembly. 5. Disconnect the cylinder head temperature sensor jumper wire connector. 6. Remove the bolt and the two studs and position the bracket out of the way. 7. Disconnect the Camshaft Position (CMP) sensor electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2010 8. Disconnect the fuel charging wiring electrical connectors from the coils and the fuel injectors. 9. Remove the wiper and cowl. 10. Disconnect the: ^ forty-two pin connector. ^ the sixteen-pin connector. ^ transmission electrical connector. 11. Remove the six bolts and five studs and remove the valve cover. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2011 1. Follow the removal procedure in reverse order: ^ Apply sealant in the locations shown; use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4. ^ Refill and check the engine oil level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Valve Guide Inner Diameter 7.015-7.044 mm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 2015 Valve Guide: Testing and Inspection For further information regarding this component, please refer to Engine; Service and Repair; General Procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 2016 Valve Guide: Service and Repair Valve-Guide Reaming 2.If the valve guide is not within specifications, ream the valve guide and install valve with an oversize stem or remove the valve guide and install new valve guide Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Diameter (Intake) 1.9-2.1 mm Valve Seat Diameter (Exhaust) 1.9-2.1 mm Valve Seat Angle 45 deg Valve Seat Runout (TIR) Max 0.025 mm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 2020 Valve Seat: Testing and Inspection For further information regarding this component, please refer to Engine; Service and Repair; General Procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Springs-Compression Pressure Intake 633.3-701.3 N at 28.02 mm Exhaust 633.3-701.3 N at 28.02 mm Valve Spring-Free Length Intake 50.2 mm Exhaust 50.2 mm Valve Springs-Installed Height 39.7-40.3 mm Valve Springs-installed Pressure Intake 272.1-306.1 N at 40.0 mm Exhaust 272.1-306.1 N at 40.0 mm Valve Springs-Installed Pressure Service Limit 3%Pressure Loss N at 28.02 mm Valve Springs-Installed Pressure Out Of Square Limit 2.5 deg Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2024 Valve Spring: Testing and Inspection For further information regarding this component, please refer to Engine; Service and Repair; General Procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2025 Valve Spring: Service and Repair Special Tools Removal 1. Remove the camshaft roller followers. 2. Position the piston at the top of the stroke. 3. Remove the spark plug and install compressed air in the cylinder to hold both valves in position. 4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. Use the Valve Spring Compressor to compress the valve springs. 5. Remove the (A) valve spring retainer keys, the (B) valve spring retainers, and the (C) valve spring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2026 Installation 1. Position the valve spring and the valve spring retainers. 2. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 3. Use the Valve Spring Compressor to compress the valve spring. Install the valve spring retainer keys. 4. Install the camshaft roller followers. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2027 Valve Spring: Tools and Equipment Special Tools Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve StemTo Guide Clearance(Intake) (0.00078-0.00270) in Valve Stem To Guide Clearance(Exhaust) (0.018-0.0037) in Valve Head Diameter(Intake) 1.75 in Valve Head Diameter(Exhaust) 1.34 in Valve Head Diameter-Gauge Diameters (1.26-1.67) in Valve Face Width 1.91-2.16 Valve Face Runout Limit 0.002 in Valve Face Angle 45.5 deg Valve Stem Diameter(STD)-Intake (0.2746-0.275) in Valve Stem Diameter(STD)-Exhaust (0.2736-0.274) in Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 2031 Valve: Testing and Inspection For further information regarding this component, please refer to Engine; Service and Repair; General Procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 2032 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Drive Belt: Specifications Drive Belt Tension See Note Newly Installed-Refers To The Condition Of The NEW Drive Belt Before The Engine Has Made No More Than One Revolution And Before The Belt Has Had A Chance To Stretch Or Seat Into The Pulley Grooves Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 2037 Drive Belt: Diagrams Part 1 Of 2 Part 2 Of 2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 2038 Drive Belt: Service and Repair Removal 1. Rotate the tensioner clockwise and remove the drive belt. Installation 1. CAUTION: Incorrect drive belt installation will cause drive belt failure. NOTE: Make sure the drive belt is correctly installed on each pulley. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair Drive Belt Tensioner: Service and Repair Removal 1. Remove the drive belt. 2. Remove the: 1 bolts. 2 belt guide. 3 drive belt tensioner. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2046 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2047 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2048 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2049 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2050 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2051 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2052 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2053 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2054 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2055 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2056 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2057 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2058 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2059 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2060 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2061 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2062 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2063 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2064 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2065 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2066 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2067 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2068 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2069 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2070 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2071 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2072 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2073 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2074 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2075 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2076 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2077 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2078 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2079 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2080 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2081 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2082 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2083 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2084 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2085 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2086 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2087 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2088 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2089 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2090 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2091 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2092 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2093 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2094 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2095 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2096 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2097 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2098 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2099 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2101 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2102 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2103 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2104 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2105 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2106 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2107 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2108 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2109 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2110 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2111 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2112 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2113 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2114 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2115 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2116 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2117 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2118 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2119 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2120 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2121 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2122 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2123 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2124 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2125 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2126 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2127 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2128 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2129 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2130 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2131 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2132 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2133 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2134 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2135 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2136 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2137 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2138 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2139 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2140 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2141 Engine Mount: Technical Service Bulletins Engine Mounts - Unsatisfactory for Severe Conditions Article No. 01-1-1 01/22/01 ENGINE MOUNTS - REVISED ENGINE MOUNTS FOR SEVERE DUTY VEHICLES FORD: 1998-2000 CROWN VICTORIA LINCOLN: 1998-2000 TOWN CAR MERCURY: 1998-2000 GRAND MARQUIS This article is being republished in its entirety to update the model year coverage and part numbers. ISSUE The engine mounts on some vehicles may not exhibit satisfactory durability under severe operating conditions that may be encountered by Police, Taxi or Limo/Livery vehicles such as extended idling at high ambient temperatures. This may be caused by the extreme heat generated by the engine under these conditions. ACTION If service to the engine mounts is required, install new revised engine mounts which incorporate a heat shield. For left side engine mount, use 1W7Z-6038-BA - right side engine mount, use 1W7Z-6038-AA. Refer to the appropriate model/year Workshop Manual, Section 303-01 for replacement procedure. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-21-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 499000, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2142 Engine Mount: Specifications Engine Mounts 39-53 ft.lb Engine Support Insulator Bolts 15-22 ft.lb Motor Mount To Crossmember 39-53 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH Engine Mount: Service and Repair LH Removal 1. Remove the oil level indicator tube. 2. Suitably support the engine. 3. Remove the three bolts. 4. Remove the three bolts. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2145 Engine Mount: Service and Repair RH Removal 1. Remove the starter. 2. Suitably support the engine. 3. Remove the three bolts. 4. Remove the three bolts. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Belt Idler Pulley 15-22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 2149 Idler Pulley: Service and Repair Removal 1. Remove the drive belt. 2. Remove the (A) bolt and the (B) belt idler pulley. Installation To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure 40-70 psi Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil Filler Dipstick Tube ......................................................................................................................... ....................................................... 71-106 inch lbs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2157 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Removal 1. Remove the exhaust manifold. 2. Remove the oil level indicator tube. ^ Remove the bolt. ^ Remove the tube. 3. Inspect the O-ring. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2162 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2163 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2164 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2165 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity ............................................................................................................................................... ................................................ 6.24L (6.6 Qt +/- 0.1) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2168 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 NOTE: Refer to TSB# 02-1-9 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2169 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adapter Bolts ......................................................................................................................... ............................................................ 15-22 ft. lbs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Locations > Non Trailer Tow and Police Option Oil Filter Adapter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Locations > Non Trailer Tow and Police Option > Page 2175 Oil Filter Adapter: Locations Trailer Tow and Police Option Oil Filter Adapter (Trailer Tow and Police Option) Oil Filter Adapter (Trailer Tow and Police Option) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Removal Oil Filter Adapter: Service and Repair Removal 1. Drain the cooling system. 2. Disconnect the lower radiator hose from the oil filter adapter. 3. Raise the vehicle. 4. Drain the engine oil. 5. Remove the oil bypass filter. 6. Remove the oil pressure sensor. 1. Disconnect the connector. 2. Remove the oil pressure sensor. 7. NOTE: On vehicles equipped with an oil cooler adapter, separate the wiring harness from the side of the oil filter adapter. On vehicles with a standard oil filter adapter, remove the harness pushpin from the oil filter adapter. Remove the oil filter adapter. ^ Remove the bolts. ^ Remove the oil filter adapter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Removal > Page 2178 Oil Filter Adapter: Service and Repair Installation 1. Clean the sealing surfaces. 2. Install a new gasket. 3. Install the oil filter adapter and tighten in the sequence shown. 4. Install the oil pressure sensor. 5. Connect the connector. 6. Install the oil bypass filter. 7. Lower the vehicle. 8. Fill the crankcase with clean Ford Super Premium SAE 5W30 Motor Oil or equivalent meeting Ford specification. 9. Connect the lower radiator hose. 10. Fill and bleed the cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts Stage 1 18 in.lb Stage 2 15 ft.lb Stage 3 Rotate 60 Degrees Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2182 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2183 Oil Pan: Service and Repair Removal 1. Remove the air cleaner outlet tube. 2. Remove the wiper arm and pivot shaft assembly. 3. Remove the drive belt. 4. Remove the fan motor and shroud assembly. 5. Disconnect the fuel lines. 6. Remove the Exhaust Gas Recirculation (EGR) tube. 7. Remove the generator. 8. Remove the blower motor speed control. 9. Remove the RH engine mount bolt. 10. Remote the two LH engine mount bolts. 11. Remove the four nuts and support the exhaust. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2184 12. Remove the bolt for the transmission line support bracket. 13. Loosen the nuts for the transmission mount. 14. Lower the vehicle. 15. NOTE: The RH motor mount has a second bolt accessed from the top. Remove the bolt. 16. Using the special tool, raise the engine with a suitable floor crane. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2185 17. Using the special tool, support the engine. 18. Raise the vehicle. 19. Remove the oil pan bolts. 20. Position the oil pan aside and remove the bolts from the oil pickup tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2186 21. Remove the bolt from the oil pickup tube bracket. 22. Remove the O-ring and inspect. 23. Remove the oil pan and gasket from the vehicle through the front. Installation 1. Install the oil pan and gasket on the vehicle. 2. Install the O-ring, using a new one if necessary. 3. Position the oil pickup tube and tighten the bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2187 4. Install and tighten the bolts. 5. Tighten the nuts. 6. Install and tighten the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2188 7. Reposition the exhaust and tighten the nuts. 8. Install and tighten the bolts. 9. Install and tighten the bolt. 10. Lower the vehicle. 11. Using the special tool, and a suitable floor crane, raise the engine and remove the special tool. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2189 12. Remove the special tool. 13. Tighten the bolt. 14. Remove the engine lift bracket. 15. Install the blower motor speed control. 16. Install the generator. 17. Install the EGR tube. 18. Connect the fuel lines. 19. Install the air cleaner outlet tube. 20. Install the wiper arm and pivot shaft assembly. 21. Install the drive belt. 22. Install the fan motor and shroud assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Engine Oil Pressure Switch: Locations 1. Oil Pressure Sensor 2. Oil Pressure Sensor Connector Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Page 2193 Engine Oil Pressure Switch: Service and Repair Removal 1. Remove the oil pressure sensor oil pressure sensor: 1 Disconnect the wire. 2 Remove the oil pressure sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation The low oil pressure warning indicator illuminates when the oil pressure switch opens, indicating oil pressure that is below the normal range. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 40-70 psi Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage Technical Service Bulletin # 05N04 Date: 051214 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2209 Attachment I - Administrative Information OASIS ACTIVATED? Yes. Affected vehicles will be activated in OASIS on December 14, 2005. FSA VIN LIST ACTIVATED? No. STOCK VEHICLES Do not perform this program unless the affected vehicle exhibits the covered condition (fix only if the coolant crossover duct is leaking). Stock vehicles are not eligible for refunds without an original receipt. SOLD VEHICLES Owners with affected vehicles that exhibit the covered condition will be directed to dealers for repairs. Owners who have paid for this repair within seven years of the warranty start date will also be directed to dealers to submit for reimbursement. Repairs that were performed after December 16 2005 will not be eligible for a refund unless an emergency repair was needed and a Ford or Lincoln Mercury dealer was not available. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2210 It is highly unlikely that you will encounter related damage while performing this repair but if a related damage condition exists that you believe to be caused by the covered condition call the Special Service Support Center to request approval prior to the repair of any related damage. Components such as ignition coils engines alternators spark plugs and spark plug wires are examples that are not covered by this program. Requests for approval after completion of the repair will not be granted. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. OWNER REFUNDS ^ Program 05N04 covers one intake manifold replacement per vehicle. Program 46B01 covers one refund per vehicle. The replacement program will show on OASIS as 05N04 and the refund program will show as 46B01. If you receive a refund request for a vehicle that no longer has 46B01 open on OASIS call the Special Service Support Center for prior approval. ^ Ford Motor Company will only refund owner-paid repairs covered by 46B01 if the repair was performed prior to December 16, 2005. (or after December 16, 2005 if an emergency repair was made when a Ford Lincoln or Mercury dealer was not available.) ^ The repair must have been completed within 7 years of the warranty start date to be eligible for a refund. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. (Requires prior approval) ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. (Requires prior approval) ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2211 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. RECALL PARTS ASSISTANCE There are three methods to use for questions or assistance regarding recall parts: ^ Parts Support Center Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2212 ^ E-mail ^ FAX Number When contacting the Parts Support Center via phone FAX or E-mail for a question or concern please provide: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA # : Customer Satisfaction Program 05N04 ^ Include a VIN # ^ Part number that you have a question / concern with DEALER PRICE For latest prices refer to DOES II. PARTS RETENTION AND RETURN Affected intake manifolds are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." Attachment III - Technical Information OVERVIEW This program involves either: A) inspecting the intake manifold part number to determine if the owner is eligible for reimbursement for a previous intake manifold replacement repair without a receipt, or B) inspecting the intake manifold coolant crossover directly behind the alternator for leakage in the event the owner reports a suspected coolant leak. If a leak in this specific area is verified, the intake manifold must be replaced. Proceed to the appropriate inspection procedure. PART NUMBER INSPECTION NOTE: The part number is molded into the intake manifold and is located between two (2) runners on the driver side of the manifold. No disassembly is required to view the part number except for removal of the engine appearance cover, if equipped. ^ On most affected vehicles, the throttle body points toward the driver side of the vehicle. The part number will be found on the driver side of the manifold, beneath the throttle body intake tube. ^ On applications where the throttle body is pointing toward the right side of the vehicle, the part number is still located on the driver side of the manifold. 1. Remove the engine appearance cover, if equipped. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2213 2. Locate the area on the intake manifold where the part number is to be found. See Figure 1. 3. NOTE: Thorough cleaning of the area is required in order to accurately read the part number prefix and suffix. Wrap a shop towel around the end of either a long screwdriver or long extension to reach the affected area to wipe after spraying with cleaner. Clean the area between the two (2) runners by first blowing any dirt or foreign material away using compressed air. Then spray the area with Motorcraft Metal Brake Parts Cleaner, PM-4 or equivalent, and using a shop towel, wipe the area clean. 4. Read and record the intake manifold part number. ^ If the part number on the manifold matches the part numbers listed, the vehicle is not eligible for a refund without a receipt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2214 ^ If the part number is different than the numbers listed below, the vehicle is eligible for a refund without a receipt. COOLANT LEAKAGE INSPECTION 1. NOTE: To properly inspect the intake manifold you must look down behind the alternator. Inspect the coolant crossover area of the intake manifold as shown in Figure 2 for engine coolant leakage. ^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop Manual, Section 303-01 for 1996 through 1998 model year vehicles and Section 303-01 for 1999 through 2002 model year vehicles for replacement procedures for intake manifold. ^ If seepage is NOT present, no service action is required. Owner Letter Owner Letter not applicable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage Technical Service Bulletin # 01M02 Date: 010301 Campaign - Intake Manifold Additional Warranty Coverage 01M02 OWNER NOTIFICATION PROGRAM Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed in the Following Vehicles: ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Owner Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2219 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2220 Attachment I - Administrative Information Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed In: - Certain 1996 through 2001 Model Year Crown Victoria Police Interceptor - Certain 1998 through 2001 Model Year Crown Victoria with Taxi Prep Package - Certain 1998 through 2001 Lincoln Town Car Limousine and Livery Prep Package OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: On an "M" program, the VIN number will remain in OASIS until the time limit of the program expires. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repair made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer.) Refer to ACESII manual for refund information. Program Code: 01M02 Misc. Expense: REFUND Misc. Expense: ADMIN Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2221 Misc. Expense: 0.2 Hr. Refer to ACESII manual for refund information. RENTAL CARS Rental vehicle coverage is not included under this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PLEASE NOTE: The labor times in the above table reflect the latest corporate standards for determining labor times. These times apply to Owner Notification Program 01M02 and are not retroactive to previous repairs. PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted. DOR/COR NUMBER DOR/COR Number 50218 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2222 DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information INSPECTION NOTE: To properly inspect the intake manifold you must look down behind the alternator. 1. Inspect the coolant crossover area of the intake manifold as shown in Figure 1 for engine coolant seepage. ^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop Manual section 03-01 for 1996 through 1998 model year vehicles and section 303-01 for 1999 through 2001 model year vehicles for replacement procedures for intake manifold. ^ If seepage is NOT present, no service action is required. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2223 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2224 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage Intake Manifold: Customer Interest Intake Manifold - Cross-Over Channel Coolant Seepage Article No. 02-2-2 02/04/02 ^ COOLANT - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER - VEHICLES EQUIPPED WITH 4.6L 2V ENGINE ONLY ^ ENGINE - 4.6L 2V - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER FORD: 1996-1997 THUNDERBIRD 1996-2001 CROWN VICTORIA, MUSTANG 2002 EXPLORER LINCOLN: 1996-2001 TOWN CAR MERCURY: 1996-1997 COUGAR 1996-2001 GRAND MARQUIS ISSUE Some vehicles may exhibit an Intake Manifold crossover (first runner) coolant seepage condition. This may be caused by a crack in the Intake Manifold coolant crossover. ACTION Inspect the suspect Intake Manifold for a coolant leak at the first runner cross-over area (Figure 1). If coolant seepage is found in this area, order the appropriate Service Kit and install parts, by referring to the appropriate Model Year Workshop Manual (Section 303-01). 4.6L 2V INTAKE MANIFOLD INSPECTION/REPLACEMENT Refer to Figure 1 for inspection of coolant seepage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage > Page 2230 If seepage is found, order one of the following Service Kits to repair. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage > Page 2231 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000, 499000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage Technical Service Bulletin # 05N04 Date: 051214 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2237 Attachment I - Administrative Information OASIS ACTIVATED? Yes. Affected vehicles will be activated in OASIS on December 14, 2005. FSA VIN LIST ACTIVATED? No. STOCK VEHICLES Do not perform this program unless the affected vehicle exhibits the covered condition (fix only if the coolant crossover duct is leaking). Stock vehicles are not eligible for refunds without an original receipt. SOLD VEHICLES Owners with affected vehicles that exhibit the covered condition will be directed to dealers for repairs. Owners who have paid for this repair within seven years of the warranty start date will also be directed to dealers to submit for reimbursement. Repairs that were performed after December 16 2005 will not be eligible for a refund unless an emergency repair was needed and a Ford or Lincoln Mercury dealer was not available. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2238 It is highly unlikely that you will encounter related damage while performing this repair but if a related damage condition exists that you believe to be caused by the covered condition call the Special Service Support Center to request approval prior to the repair of any related damage. Components such as ignition coils engines alternators spark plugs and spark plug wires are examples that are not covered by this program. Requests for approval after completion of the repair will not be granted. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. OWNER REFUNDS ^ Program 05N04 covers one intake manifold replacement per vehicle. Program 46B01 covers one refund per vehicle. The replacement program will show on OASIS as 05N04 and the refund program will show as 46B01. If you receive a refund request for a vehicle that no longer has 46B01 open on OASIS call the Special Service Support Center for prior approval. ^ Ford Motor Company will only refund owner-paid repairs covered by 46B01 if the repair was performed prior to December 16, 2005. (or after December 16, 2005 if an emergency repair was made when a Ford Lincoln or Mercury dealer was not available.) ^ The repair must have been completed within 7 years of the warranty start date to be eligible for a refund. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. (Requires prior approval) ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. (Requires prior approval) ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2239 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. RECALL PARTS ASSISTANCE There are three methods to use for questions or assistance regarding recall parts: ^ Parts Support Center Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2240 ^ E-mail ^ FAX Number When contacting the Parts Support Center via phone FAX or E-mail for a question or concern please provide: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA # : Customer Satisfaction Program 05N04 ^ Include a VIN # ^ Part number that you have a question / concern with DEALER PRICE For latest prices refer to DOES II. PARTS RETENTION AND RETURN Affected intake manifolds are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." Attachment III - Technical Information OVERVIEW This program involves either: A) inspecting the intake manifold part number to determine if the owner is eligible for reimbursement for a previous intake manifold replacement repair without a receipt, or B) inspecting the intake manifold coolant crossover directly behind the alternator for leakage in the event the owner reports a suspected coolant leak. If a leak in this specific area is verified, the intake manifold must be replaced. Proceed to the appropriate inspection procedure. PART NUMBER INSPECTION NOTE: The part number is molded into the intake manifold and is located between two (2) runners on the driver side of the manifold. No disassembly is required to view the part number except for removal of the engine appearance cover, if equipped. ^ On most affected vehicles, the throttle body points toward the driver side of the vehicle. The part number will be found on the driver side of the manifold, beneath the throttle body intake tube. ^ On applications where the throttle body is pointing toward the right side of the vehicle, the part number is still located on the driver side of the manifold. 1. Remove the engine appearance cover, if equipped. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2241 2. Locate the area on the intake manifold where the part number is to be found. See Figure 1. 3. NOTE: Thorough cleaning of the area is required in order to accurately read the part number prefix and suffix. Wrap a shop towel around the end of either a long screwdriver or long extension to reach the affected area to wipe after spraying with cleaner. Clean the area between the two (2) runners by first blowing any dirt or foreign material away using compressed air. Then spray the area with Motorcraft Metal Brake Parts Cleaner, PM-4 or equivalent, and using a shop towel, wipe the area clean. 4. Read and record the intake manifold part number. ^ If the part number on the manifold matches the part numbers listed, the vehicle is not eligible for a refund without a receipt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2242 ^ If the part number is different than the numbers listed below, the vehicle is eligible for a refund without a receipt. COOLANT LEAKAGE INSPECTION 1. NOTE: To properly inspect the intake manifold you must look down behind the alternator. Inspect the coolant crossover area of the intake manifold as shown in Figure 2 for engine coolant leakage. ^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop Manual, Section 303-01 for 1996 through 1998 model year vehicles and Section 303-01 for 1999 through 2002 model year vehicles for replacement procedures for intake manifold. ^ If seepage is NOT present, no service action is required. Owner Letter Owner Letter not applicable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage Intake Manifold: All Technical Service Bulletins Intake Manifold - Cross-Over Channel Coolant Seepage Article No. 02-2-2 02/04/02 ^ COOLANT - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER - VEHICLES EQUIPPED WITH 4.6L 2V ENGINE ONLY ^ ENGINE - 4.6L 2V - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER FORD: 1996-1997 THUNDERBIRD 1996-2001 CROWN VICTORIA, MUSTANG 2002 EXPLORER LINCOLN: 1996-2001 TOWN CAR MERCURY: 1996-1997 COUGAR 1996-2001 GRAND MARQUIS ISSUE Some vehicles may exhibit an Intake Manifold crossover (first runner) coolant seepage condition. This may be caused by a crack in the Intake Manifold coolant crossover. ACTION Inspect the suspect Intake Manifold for a coolant leak at the first runner cross-over area (Figure 1). If coolant seepage is found in this area, order the appropriate Service Kit and install parts, by referring to the appropriate Model Year Workshop Manual (Section 303-01). 4.6L 2V INTAKE MANIFOLD INSPECTION/REPLACEMENT Refer to Figure 1 for inspection of coolant seepage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage > Page 2247 If seepage is found, order one of the following Service Kits to repair. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage > Page 2248 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000, 499000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage Technical Service Bulletin # 01M02 Date: 010301 Campaign - Intake Manifold Additional Warranty Coverage 01M02 OWNER NOTIFICATION PROGRAM Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed in the Following Vehicles: ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Owner Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2253 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2254 Attachment I - Administrative Information Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed In: - Certain 1996 through 2001 Model Year Crown Victoria Police Interceptor - Certain 1998 through 2001 Model Year Crown Victoria with Taxi Prep Package - Certain 1998 through 2001 Lincoln Town Car Limousine and Livery Prep Package OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: On an "M" program, the VIN number will remain in OASIS until the time limit of the program expires. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repair made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer.) Refer to ACESII manual for refund information. Program Code: 01M02 Misc. Expense: REFUND Misc. Expense: ADMIN Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2255 Misc. Expense: 0.2 Hr. Refer to ACESII manual for refund information. RENTAL CARS Rental vehicle coverage is not included under this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PLEASE NOTE: The labor times in the above table reflect the latest corporate standards for determining labor times. These times apply to Owner Notification Program 01M02 and are not retroactive to previous repairs. PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted. DOR/COR NUMBER DOR/COR Number 50218 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2256 DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information INSPECTION NOTE: To properly inspect the intake manifold you must look down behind the alternator. 1. Inspect the coolant crossover area of the intake manifold as shown in Figure 1 for engine coolant seepage. ^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop Manual section 03-01 for 1996 through 1998 model year vehicles and section 303-01 for 1999 through 2001 model year vehicles for replacement procedures for intake manifold. ^ If seepage is NOT present, no service action is required. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2257 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2258 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage Intake Manifold: All Technical Service Bulletins Intake Manifold - Cross-Over Channel Coolant Seepage Article No. 02-2-2 02/04/02 ^ COOLANT - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER - VEHICLES EQUIPPED WITH 4.6L 2V ENGINE ONLY ^ ENGINE - 4.6L 2V - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER FORD: 1996-1997 THUNDERBIRD 1996-2001 CROWN VICTORIA, MUSTANG 2002 EXPLORER LINCOLN: 1996-2001 TOWN CAR MERCURY: 1996-1997 COUGAR 1996-2001 GRAND MARQUIS ISSUE Some vehicles may exhibit an Intake Manifold crossover (first runner) coolant seepage condition. This may be caused by a crack in the Intake Manifold coolant crossover. ACTION Inspect the suspect Intake Manifold for a coolant leak at the first runner cross-over area (Figure 1). If coolant seepage is found in this area, order the appropriate Service Kit and install parts, by referring to the appropriate Model Year Workshop Manual (Section 303-01). 4.6L 2V INTAKE MANIFOLD INSPECTION/REPLACEMENT Refer to Figure 1 for inspection of coolant seepage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage > Page 2264 If seepage is found, order one of the following Service Kits to repair. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage > Page 2265 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000, 499000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage Technical Service Bulletin # 05N04 Date: 051214 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2271 Attachment I - Administrative Information OASIS ACTIVATED? Yes. Affected vehicles will be activated in OASIS on December 14, 2005. FSA VIN LIST ACTIVATED? No. STOCK VEHICLES Do not perform this program unless the affected vehicle exhibits the covered condition (fix only if the coolant crossover duct is leaking). Stock vehicles are not eligible for refunds without an original receipt. SOLD VEHICLES Owners with affected vehicles that exhibit the covered condition will be directed to dealers for repairs. Owners who have paid for this repair within seven years of the warranty start date will also be directed to dealers to submit for reimbursement. Repairs that were performed after December 16 2005 will not be eligible for a refund unless an emergency repair was needed and a Ford or Lincoln Mercury dealer was not available. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2272 It is highly unlikely that you will encounter related damage while performing this repair but if a related damage condition exists that you believe to be caused by the covered condition call the Special Service Support Center to request approval prior to the repair of any related damage. Components such as ignition coils engines alternators spark plugs and spark plug wires are examples that are not covered by this program. Requests for approval after completion of the repair will not be granted. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. OWNER REFUNDS ^ Program 05N04 covers one intake manifold replacement per vehicle. Program 46B01 covers one refund per vehicle. The replacement program will show on OASIS as 05N04 and the refund program will show as 46B01. If you receive a refund request for a vehicle that no longer has 46B01 open on OASIS call the Special Service Support Center for prior approval. ^ Ford Motor Company will only refund owner-paid repairs covered by 46B01 if the repair was performed prior to December 16, 2005. (or after December 16, 2005 if an emergency repair was made when a Ford Lincoln or Mercury dealer was not available.) ^ The repair must have been completed within 7 years of the warranty start date to be eligible for a refund. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. (Requires prior approval) ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. (Requires prior approval) ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2273 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. RECALL PARTS ASSISTANCE There are three methods to use for questions or assistance regarding recall parts: ^ Parts Support Center Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2274 ^ E-mail ^ FAX Number When contacting the Parts Support Center via phone FAX or E-mail for a question or concern please provide: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA # : Customer Satisfaction Program 05N04 ^ Include a VIN # ^ Part number that you have a question / concern with DEALER PRICE For latest prices refer to DOES II. PARTS RETENTION AND RETURN Affected intake manifolds are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." Attachment III - Technical Information OVERVIEW This program involves either: A) inspecting the intake manifold part number to determine if the owner is eligible for reimbursement for a previous intake manifold replacement repair without a receipt, or B) inspecting the intake manifold coolant crossover directly behind the alternator for leakage in the event the owner reports a suspected coolant leak. If a leak in this specific area is verified, the intake manifold must be replaced. Proceed to the appropriate inspection procedure. PART NUMBER INSPECTION NOTE: The part number is molded into the intake manifold and is located between two (2) runners on the driver side of the manifold. No disassembly is required to view the part number except for removal of the engine appearance cover, if equipped. ^ On most affected vehicles, the throttle body points toward the driver side of the vehicle. The part number will be found on the driver side of the manifold, beneath the throttle body intake tube. ^ On applications where the throttle body is pointing toward the right side of the vehicle, the part number is still located on the driver side of the manifold. 1. Remove the engine appearance cover, if equipped. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2275 2. Locate the area on the intake manifold where the part number is to be found. See Figure 1. 3. NOTE: Thorough cleaning of the area is required in order to accurately read the part number prefix and suffix. Wrap a shop towel around the end of either a long screwdriver or long extension to reach the affected area to wipe after spraying with cleaner. Clean the area between the two (2) runners by first blowing any dirt or foreign material away using compressed air. Then spray the area with Motorcraft Metal Brake Parts Cleaner, PM-4 or equivalent, and using a shop towel, wipe the area clean. 4. Read and record the intake manifold part number. ^ If the part number on the manifold matches the part numbers listed, the vehicle is not eligible for a refund without a receipt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2276 ^ If the part number is different than the numbers listed below, the vehicle is eligible for a refund without a receipt. COOLANT LEAKAGE INSPECTION 1. NOTE: To properly inspect the intake manifold you must look down behind the alternator. Inspect the coolant crossover area of the intake manifold as shown in Figure 2 for engine coolant leakage. ^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop Manual, Section 303-01 for 1996 through 1998 model year vehicles and Section 303-01 for 1999 through 2002 model year vehicles for replacement procedures for intake manifold. ^ If seepage is NOT present, no service action is required. Owner Letter Owner Letter not applicable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage Technical Service Bulletin # 01M02 Date: 010301 Campaign - Intake Manifold Additional Warranty Coverage 01M02 OWNER NOTIFICATION PROGRAM Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed in the Following Vehicles: ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Owner Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2281 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2282 Attachment I - Administrative Information Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed In: - Certain 1996 through 2001 Model Year Crown Victoria Police Interceptor - Certain 1998 through 2001 Model Year Crown Victoria with Taxi Prep Package - Certain 1998 through 2001 Lincoln Town Car Limousine and Livery Prep Package OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: On an "M" program, the VIN number will remain in OASIS until the time limit of the program expires. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repair made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer.) Refer to ACESII manual for refund information. Program Code: 01M02 Misc. Expense: REFUND Misc. Expense: ADMIN Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2283 Misc. Expense: 0.2 Hr. Refer to ACESII manual for refund information. RENTAL CARS Rental vehicle coverage is not included under this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PLEASE NOTE: The labor times in the above table reflect the latest corporate standards for determining labor times. These times apply to Owner Notification Program 01M02 and are not retroactive to previous repairs. PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted. DOR/COR NUMBER DOR/COR Number 50218 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2284 DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information INSPECTION NOTE: To properly inspect the intake manifold you must look down behind the alternator. 1. Inspect the coolant crossover area of the intake manifold as shown in Figure 1 for engine coolant seepage. ^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop Manual section 03-01 for 1996 through 1998 model year vehicles and section 303-01 for 1999 through 2001 model year vehicles for replacement procedures for intake manifold. ^ If seepage is NOT present, no service action is required. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2285 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2286 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2287 Intake Manifold: Specifications Throttle Body Fasteners 71-106 in.lb Fuel Injection Supply Manifold bolts 89 in.lb Upper Generator Support Bracket 71-106 in.lb Intake Manifold Bolts 15-22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal Intake Manifold: Service and Repair Removal 1. Remove the wiper arm and pivot shaft. 2. Remove the air cleaner outlet tube. 3. Disconnect the fuel line. 4. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils and the eight fuel injectors. 5. Disconnect the fuel charging wiring electrical connector from the fuel pressure sensor. 6. Disconnect the fuel charging wiring electrical connector from the fuel temperature sensor. 7. Disconnect the fuel charging wiring electrical connector from the engine coolant temperature sensor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2290 8. Separate the isolation valve wiring lead from the upper generator support bracket and disconnect. 9. Disconnect the generator battery cable. 10. Remove the power distribution box access cover. 11. Remove the nut and the wiring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2291 12. Disconnect the fuel charging wiring electrical connectors at the inner fender splash shield. 13. Disconnect the fuel charging wiring electrical connector from the A/C pressure transducer. 14. Disconnect the fuel charging wiring electrical connector from the cylinder head temperature sensor jumper. 15. Disconnect the fuel charging wiring electrical connector from the camshaft position sensor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2292 16. Disconnect the fuel charging wiring electrical connector from the generator. 17. Disconnect the fuel charging wiring electrical connector from the throttle position sensor. 18. Disconnect the fuel charging wiring from the radio ignition interference capacitor. 19. Disconnect the fuel charging wiring from the EGR vacuum regulator solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2293 20. Disconnect the fuel charging wiring from the differential pressure feedback EGR. 21. Disconnect the fuel charging wiring from the idle air control valve. 22. Disconnect the throttle cable and the speed control actuator cable from the throttle body. 23. Remove the bolts and position the cables and bracket out of the way. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2294 24. Remove the bolts and position the fuel charging wiring out of the way. 25. Disconnect the fuel lines. 26. Disconnect the hoses from the differential pressure feedback EGR. 27. Disconnect the vacuum line from the Exhaust Gas Recirculation (EGR) valve. 28. Disconnect the main chassis vacuum supply line from the throttle body adapter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2295 29. Disconnect the crankcase ventilation tube at two locations and remove from the vehicle. 30. Disconnect the vacuum line from the throttle body adapter. 31. Disconnect the vacuum lines from the EGR vacuum regulator solenoid. 32. Disconnect the EGR tube from the EGR valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2296 33. Remove the bolts from the isolation valve. 34. Remove the four bolts. 35. Remove the fuel injection supply manifold and the fuel injectors as an assembly. 36. Disconnect the heater water hose from the intake manifold. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2297 37. Disconnect the upper radiator hose from the water outlet adapter. 38. Remove the bolts and the eight ignition coils. 39. Remove the bolts and the upper generator support bracket. 40. Remove the bolts and the water outlet adapter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2298 41. Remove the water thermostat and the O-ring. 42. Remove the bolts. 43. Remove the intake manifold. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2299 44. Remove the intake manifold gaskets. 45. Clean the sealing surfaces. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2300 Intake Manifold: Service and Repair Installation 1. Install new intake manifold gaskets. 2. Install the intake manifold. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2301 3. Install the bolts and tighten in the sequence shown. 4. Install the water thermostat and a new O-ring. 5. Install the water outlet adapter and tighten the bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2302 6. Install the upper generator support bracket and tighten the bolts. 7. Install the eight ignition coils and tighten the bolts. 8. Connect the upper radiator hose to the water outlet adapter. 9. Connect the heater water hose to the intake manifold. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2303 10. Install the fuel injectors and the fuel injection supply manifold as an assembly. 11. Install the four bolts. 12. Install the bolts in the isolation valve and tighten. 13. Connect the EGR tube to the EGR valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2304 14. Connect the vacuum lines to the EGR vacuum regulator solenoid. 15. Connect the vacuum lines to the throttle body adapter. 16. Install the crankcase ventilation tube and connect at two locations. 17. Connect the main chassis vacuum supply line to the throttle body adapter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2305 18. Connect the vacuum line to the EGR valve. 19. Connect the hoses to the differential pressure feedback EGR. 20. Connect the fuel line. 21. Reposition the fuel charging wiring and install the bolts. 22. Reposition the cables and the bracket and install the bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2306 23. Connect the throttle cable and the speed control actuator cable to the throttle body. 24. Connect the fuel charging wiring to the idle air control valve. 25. Connect the fuel charging wiring to the differential pressure feedback EGR. 26. Connect the fuel charging wiring to the EGR vacuum regulator solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2307 27. Connect the fuel charging wiring to the radio ignition interference capacitor. 28. Connect the fuel charging wiring electrical connector to the throttle position sensor. 29. Connect the fuel charging wiring electrical connector to the generator. 30. Connect the fuel charging wiring electrical connector to the camshaft position sensor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2308 31. Connect the fuel charging wiring electrical connector to the cylinder head temperature sensor jumper. 32. Connect the fuel charging wiring electrical connector to the A/C pressure transducer.. 33. Connect the fuel charging wiring electrical connectors at the inner fender splash shield. 34. Reposition the wiring on the stud and tighten the nut. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2309 35. Install the power distribution box access cover. 36. Connect the generator battery cable and tighten the nut. 37. Connect the isolation valve jumper to the fuel charging wiring electrical connector. 38. Connect the fuel charging wiring electrical connector to the engine coolant temperature sensor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2310 39. Connect the fuel charging wiring electrical connector to the fuel temperature sensor. 40. Connect the fuel charging wiring electrical connector to the fuel pressure sensor. 41. Connect the fuel charging wiring electrical connectors to the eight ignitions coils and the eight fuel injectors. 42. Install the wiper arm and pivot shaft. 43. Install the air cleaner outlet tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation The low oil pressure warning indicator illuminates when the oil pressure switch opens, indicating oil pressure that is below the normal range. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Special Tools Special Tools Special Tools Removal 1. Remove the transmission. 2. Remove the flywheel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2319 3. Use the (A) Rear Crankshaft Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger. 4. Use the (A) Rear Crankshaft Seal Remover and the (B) Slide Hammer to remove the (C) rear main seal. 5. If the oil dye leak test reveals a leak behind the retainer, remove the eight bolts and the crankcase rear oil seal retainer. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: Clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer, failure to follow this procedure can cause future oil leakage. Clean and inspect the mating surface. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2320 2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: If the rear crankshaft seal retaining plate is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: The silicone must be applied on the groove along the retainer plate. Apply silicone around the rear oil seal retainer sealing surface. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4. 3. Install the rear oil seal retainer and loosely install the eight bolts. 4. Tighten the eight rear oil seal retainer bolts in the sequence shown. 5. NOTE: Lubricate the inner lip of the rear crankshaft seal with Ford Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the rear main seal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2321 6. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear main seal slinger. 8. Install the transmission. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket Cylinder Head Gasket: Customer Interest Engine - Oil Leak From R/H Cylinder Head Gasket Article No. 03-6-2 03/31/03 ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY" GASKET AND CYLINDER HEAD KITS AVAILABILITY FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES 2000-2001 EXCURSION LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR MERCURY: 1999-2002 GRAND MARQUIS Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line coverage. ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of the head gasket can be performed. If the head was damaged by chip contamination, the head should be replaced. A revised "Service-Only" gasket is now released for both of these cases. SERVICE INFORMATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2330 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2331 Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing area does not follow the same sealing path as the original gasket. This area is surrounding the High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure 2). Required for service are: ^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from Snap-On or as provided by Ford Motor Company) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2332 ^ Motorcraft Silicone Gasket Remover (ZC-30) ^ Metal Surface Prep (ZC-31) ^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side) with the new embossed area The engine should be allowed to cool before removing the head or warpage may occur in deck flatness. The cylinder head and block decks should be cleaned before performing a flatness check. Dark metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any residual silicone RTV with ZC-30 and ZC-31 applied in sequence. The Workshop Manual and Service Labor Time Standards have been recently updated for both cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include instructions to remove the engine prior to removing the cylinder head. Service Labor Time Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle. Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for applicability. Cylinder Head Kits include: ^ Complete Head assembly, with Cam and Valves ^ Head Bolts ^ Service Only Head Gasket ^ Both Intake Gaskets Exhaust Gasket ^ One Rocker Cover Gasket ^ One set of Exhaust Studs and Nuts If it is found that only one head is leaking, it is not necessary to remove the other head Only repair the side for which leakage occurs. For detailed information on these subjects refer to previous articles on general cylinder head gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and straightedge procedures. Parts Block OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2 SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 490000, 497000, 499000 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket Cylinder Head Gasket: All Technical Service Bulletins Engine - Oil Leak From R/H Cylinder Head Gasket Article No. 03-6-2 03/31/03 ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY" GASKET AND CYLINDER HEAD KITS AVAILABILITY FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES 2000-2001 EXCURSION LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR MERCURY: 1999-2002 GRAND MARQUIS Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line coverage. ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of the head gasket can be performed. If the head was damaged by chip contamination, the head should be replaced. A revised "Service-Only" gasket is now released for both of these cases. SERVICE INFORMATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2338 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2339 Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing area does not follow the same sealing path as the original gasket. This area is surrounding the High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure 2). Required for service are: ^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from Snap-On or as provided by Ford Motor Company) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2340 ^ Motorcraft Silicone Gasket Remover (ZC-30) ^ Metal Surface Prep (ZC-31) ^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side) with the new embossed area The engine should be allowed to cool before removing the head or warpage may occur in deck flatness. The cylinder head and block decks should be cleaned before performing a flatness check. Dark metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any residual silicone RTV with ZC-30 and ZC-31 applied in sequence. The Workshop Manual and Service Labor Time Standards have been recently updated for both cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include instructions to remove the engine prior to removing the cylinder head. Service Labor Time Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle. Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for applicability. Cylinder Head Kits include: ^ Complete Head assembly, with Cam and Valves ^ Head Bolts ^ Service Only Head Gasket ^ Both Intake Gaskets Exhaust Gasket ^ One Rocker Cover Gasket ^ One set of Exhaust Studs and Nuts If it is found that only one head is leaking, it is not necessary to remove the other head Only repair the side for which leakage occurs. For detailed information on these subjects refer to previous articles on general cylinder head gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and straightedge procedures. Parts Block OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2 SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 490000, 497000, 499000 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2345 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2346 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: All Technical Service Bulletins A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 2352 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 2353 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 2354 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket Cylinder Head Gasket: All Technical Service Bulletins Engine - Oil Leak From R/H Cylinder Head Gasket Article No. 03-6-2 03/31/03 ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY" GASKET AND CYLINDER HEAD KITS AVAILABILITY FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES 2000-2001 EXCURSION LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR MERCURY: 1999-2002 GRAND MARQUIS Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line coverage. ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of the head gasket can be performed. If the head was damaged by chip contamination, the head should be replaced. A revised "Service-Only" gasket is now released for both of these cases. SERVICE INFORMATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2364 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2365 Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing area does not follow the same sealing path as the original gasket. This area is surrounding the High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure 2). Required for service are: ^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from Snap-On or as provided by Ford Motor Company) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2366 ^ Motorcraft Silicone Gasket Remover (ZC-30) ^ Metal Surface Prep (ZC-31) ^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side) with the new embossed area The engine should be allowed to cool before removing the head or warpage may occur in deck flatness. The cylinder head and block decks should be cleaned before performing a flatness check. Dark metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any residual silicone RTV with ZC-30 and ZC-31 applied in sequence. The Workshop Manual and Service Labor Time Standards have been recently updated for both cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include instructions to remove the engine prior to removing the cylinder head. Service Labor Time Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle. Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for applicability. Cylinder Head Kits include: ^ Complete Head assembly, with Cam and Valves ^ Head Bolts ^ Service Only Head Gasket ^ Both Intake Gaskets Exhaust Gasket ^ One Rocker Cover Gasket ^ One set of Exhaust Studs and Nuts If it is found that only one head is leaking, it is not necessary to remove the other head Only repair the side for which leakage occurs. For detailed information on these subjects refer to previous articles on general cylinder head gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and straightedge procedures. Parts Block OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2 SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 490000, 497000, 499000 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2371 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 > Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2372 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Removal 1. Remove the crankshaft pulley. 2. Use the (A) Front Cover Seal Remover to remove the (B) front cover seal. Installation 1. Lubricate the (A) engine front cover and the (B) front oil seal inner lip. Use Ford Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2376 2. Use the (A) Crankshaft Seal Replacer/Cover Aligner to install the (B) crankshaft front seal into the (C) engine front cover. 3. Install the crankshaft pulley. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Special Tools Removal 1. Remove the valve springs. 2. Remove the valve stem seals. Installation 1. NOTE: The valve stem seal must be bottomed on the valve seat. NOTE: Make sure that the garter spring is present in the valve stem seal. Use the (A) Valve Stem Seal Replacer to install the (B) valve stem seals. 2. Install the valve springs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2380 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Engine Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Engine Oil Pressure Switch: Locations 1. Oil Pressure Sensor 2. Oil Pressure Sensor Connector Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Engine Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Page 2385 Engine Oil Pressure Switch: Service and Repair Removal 1. Remove the oil pressure sensor oil pressure sensor: 1 Disconnect the wire. 2 Remove the oil pressure sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications TORQUE SPECIFICATIONS Camshaft Sprocket Bolt ........................................................................................................................................................ 110-130 Nm (81-95 Ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Stage 1 66 ft.lb Stage 2 Loosen 360 Degrees Stage 3 35-39 ft.lb Stage 4 Rotate 85-90 Degrees Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Removal CAUTION: Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage may occur. 1. Remove the engine front cover. 2. Remove the roller followers. 3. Remove the (A) crankshaft sensor ring from the (B) crankshaft. 4. Rotate the crankshaft until both camshaft keyways are 90 degrees from the valve cover surface. Make sure the copper links line up with the dots on the camshaft sprocket. 5. Remove the (A) bolts and the (B) LH timing chain tensioner. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2396 6. Remove the (A) bolts and the (B) RH timing chain tensioner. 7. Remove the LH and RH timing chain tensioner arm from the dowel pins. 8. Remove the timing chains and crankshaft sprockets from the camshafts and crankshaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2397 9. Remove the timing chain guide 1 Remove the bolts. 2 Remove the LH timing chain guide. 3 Remove the bolts. 4 Remove the RH timing chain guide. Installation 1. CAUTION: The timing chain procedures must be followed exactly or damage to valves and pistons will result. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly. Compress the tensioner plunger, using an edge of a vise. 2. Using a small screwdriver or pick, push back and hold the ratchet mechanism. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2398 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation. 5. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2399 6. Install the timing chain guide. 1 Position LH timing chain guide. 2 Install and tighten the bolts. 3 Position the RH timing chain guide. 4 Install and tighten the RH bolts. 7. Install the timing chain and the crankshaft sprockets. 1 Slide the (A) crankshaft main bearing thrust washer onto the (B) crankshaft, aligning the copper link on the timing chain with the dot on the crankshaft main bearing thrust washer. 2 Position the timing chain over the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2400 8. Make sure that the (A) copper marks on the timing chain/belt are lined up with the corresponding dots on the crankshaft sprockets and the camshaft sprockets. 9. Make sure that the (A) camshaft sprocket keyway is 90 degrees from the (B) valve cover mounting surface. Fig. 26 Crankshaft Sprocket Position Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2401 10. Make sure that the (A) RH crankshaft sprocket is on the front of the (B) LH crankshaft sprocket with the long hubs facing each other. 11. Position the LH and RH timing chain tensioner arms on the dowel pins. 12. Position the RH timing chain tensioner and install the bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2402 13. Position the LH timing chain tensioner and install the bolts. 14. Remove both the RH and LH retaining pins from the timing chain tensioner. 15. Install the (A) crankshaft sensor ring on the (B) crankshaft sprocket. 16. Install the engine front cover. 17. Install the roller followers. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications LH Timing Chain Guide Bolts 71-106 in.lb RH Timing Chain Guide Bolts 71-106 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications > Page 2406 Timing Chain Guide: Service and Repair Refer to Timing Chain; Service and Repair for service of timing drive components. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioners 18 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2410 Timing Chain Tensioner: Service and Repair Refer to Timing Chain; Service and Repair for service of timing drive components. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Bolts Stage 1: Tighten Fasteners 1-7 15-22 in.lb Stage 2: Tighten Fasteners 6-15 30-41 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2414 Timing Cover: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove both valve covers. 3. Remove the water pump. 4. Raise and support the vehicle. 5. Remove the bolts and position the power steering pump aside. 6. Remove the oil pan drain plug and drain the engine oil. 7. Remove the bolts. 8. Lower the vehicle. 9. Remove the crankshaft front seal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2415 10. Remove the bolt and the belt idler pulley. 11. Remove the bolts and stud bolts. 12. Remove the engine front cover from the front-cover-to-cylinder-block dowel. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2416 1. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or for four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone along the cylinder head-to-block surface and the oil pan-to-cylinder block surface. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4. 2. Install the engine front cover on the front-cover-to-cylinder-block dowel and loosely install the bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2417 3. Tighten the front cover bolts and stud bolts in sequence in two stages. Stage 1: Tighten fasteners 1 through 7 to 20-30 Nm ( 15 -22 ft. lbs.). Stage 2: Tighten fasteners 6 through 15 to 40-55 Nm (29-40 ft. lbs.). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2418 4. Position the belt idler pulley and install the bolt. 5. Install a new engine front cover front oil seal. 6. Raise and support the vehicle. 7. Loosely install the front oil pan bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2419 8. NOTE: Make sure to tighten the bolts in two stages. Tighten the bolts in the sequence shown in two stages. 1 Tighten to 20 Nm (15 ft. lbs.). 2 Tighten an additional 60 degrees. 9. NOTE: The front lower hole in the power steering pump is not used. Position the power steering pump and install the bolts. 10. Install the oil pan drain plug. 11. Lower the vehicle. 12. Install the valve covers. 13. Install the water pump. 14. Connect the battery ground cable. 15. Fill the engine with oil. Use Ford Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Fuel Rail Pressure 105 - 130 psi Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 2425 Fuel Pressure: Specifications Volume Flow ..................................................................................................................................................... ................................................................. 160 lbs/hr Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed Idle Speed Hot Idle 790-815 rpm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. On gasoline vehicles, remove the engine appearance cover. ^ Loosen the retainer. ^ Remove the cover. 2. Remove the idle air control valve inlet tube. 3. Remove the crankcase ventilation hose. 4. Loosen the clamps and remove the air cleaner outlet tube. NOTE: Gasoline shown, natural gas similar. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2433 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 REMOVAL 1. Release the metal clips. 2. Lift the cover. 3. Remove the Air Cleaner (ACL) element. INSTALLATION 1. To install,reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2442 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Typical Vent Stack Installation NOTE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2443 ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2444 Fuel Pressure Release: Service and Repair Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2445 minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2446 Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2447 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2448 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2449 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2450 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2451 Typical Vent Stack Installation NOTE ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2452 ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2453 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2454 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2455 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2456 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Open 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open as necessary. Disconnect the electrical Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2457 connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Ground Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2458 6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as stuck open. 8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The pressure should be at or near 0 kPa (0 psi). 10. Remove the fuel tank solenoid manual lock-down valve. 11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2459 12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops. 14. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 15. Perform the fuel line venting procedure. 16. Remove the Manual Override Tool from the fuel tank solenoid valve. 17. Install the fuel tank solenoid manual lock~down valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2460 18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Closed 1. Connect the Grounding Cable to the back side of NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2461 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the manual bleed valve on the Fuel Filler Neck Venting Kit. 7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2462 8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 9. Turn in the Manual Override Tool jackscrew until fuel flows. 10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure reading should be at tank pressure. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Vent the fuel tank until the fuel flow stops. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 2463 13. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 14. Perform the fuel line venting procedure. 15. Remove the Manual Override Tool from the fuel tank solenoid valve. 16. Install the fuel tank solenoid manual lock-down valve. 17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order 1-3-7-2-6-5-4-8 Coil On Plug Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plugs 20 Nm Spark Plug Gap 1.32-1.42 mm Spark Plug Type AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2475 Spark Plug: Specifications Spark Plugs 20 Nm Spark Plug Gap 1.32-1.42 mm Spark Plug Type AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2476 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................................................... AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2477 Spark Plug: Description and Operation The spark plugs: ^ change a high voltage pulse into a spark which ignites the fuel and air mixture. ^ originally equipped on the vehicle have a platinum-enhanced active electrode for long life. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2478 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil. 2. Remove the spark plugs. NOTE: Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 3. Inspect the spark plugs for a gap bridged. ^ Check for deposit build-up closing the gap between electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 4. Inspect 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2479 5. Inspect for carbon fouling, identified by black, dry, fluffy carbon deposits on insulator tips, exposed shell surfaces and electrodes. This is caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 6. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 7. Inspect for pre-ignition, ^ identified by melted electrodes and possibly a damaged insulator. Metallic deposits on the insulator indicate engine damage, which may be caused by incorrect ignition timing, wrong type of fuel or the installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 8. Inspect for overheating, identified by a white or light gray insulator with small black or gray-brown spots with bluish-burnt appearance of electrodes. This can be caused by engine overheating, the wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2480 ^ Install a new spark plug. 9. Inspect for fused spot deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. 10. Adjust the spark plug gap as required. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart (Part 1 Of 2) Compression Pressure Limit Chart (Part 2 Of 2) The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2484 Compression Check: Testing and Inspection Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Pressure Limit Chart (Part 1 Of 2) Compression Pressure Limit Chart (Part 2 Of 2) Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2485 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump 15-22 ft.lb Water Pump Pulley 15-22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2492 Water Pump: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Drain the coolant. 2. Loosen the bolts. 3. Remove the belt. 4. Remove the bolts and the water pump pulley. 5. Remove the four bolts from the water pump. 6. Remove the water pump. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2493 7. Clean water pump mounting surface. Installation 1. CAUTION: Do not rotate the water pump housing once installed in the engine. Damage to the O-ring can occur, causing the water pump to leak. NOTE: Install a new O-ring seal and lubricate with Ford Premium Engine Coolant E2FZ-19549-AA, F5FZ-19549-CC in Oregon, CXC-10 in Canada or equivalent meeting Ford Specification ESE-M97B44-A. To install, reverse the removal procedure. 2. Fill the cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2499 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Cooling System 15 L Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2502 Coolant: Fluid Type Specifications Coolant Type ....................................................................................................................................... ................................ Ford Premium Engine Coolant Ford Specification................................................................................................................................. .........................................................ESE-M97B44-A Note: Use Ford Premium Engine Coolant (green in color). DO NOT USE Ford Extended LIfe Engine Coolant (orange in color). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2503 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Cylinder Block Drain Plug 16-24 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Degas Bottle Bolts ............................................................................................................................... ............................................. 8-12 Nm (71-106 lb in) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 2510 Coolant Reservoir: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. NOTE: Drain coolant from the degas bottle only. Remove the degas bottle supply hose. 2. Remove the overflow hose. 3. Remove the bolt and the degas bottle. Installation 1. Follow the removal procedure in reverse order. 2. Fill the cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM Engine Spark Knock While Accelerating > Page 2520 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM Engine Spark Knock While Accelerating > Page 2521 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 02-9-7 > May > 02 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 02-9-7 > May > 02 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2531 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > 02-9-7 > May > 02 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2532 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Control Module: > Page 2533 Clutch: Specifications Clearance 0.062 - 0.85 in Snap Ring Thickness 0.050 - 0.054 0.064 - 0.068 0.078 - 0.082 0.092 - 0.096 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2542 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2543 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure Technical Service Bulletin # 03-2-6 Date: 030203 Cooling System - Cooling Fan Motor Service Procedure Article No. 03-2-6 03/02/03 ^ ELECTRICAL - REVISED COOLING FAN MOTOR AVAILABLE ^ COOLING - REVISED COOLING FAN MOTOR AVAILABLE FORD: 1998-2000 CROWN VICTORIA MERCURY: 1998-2000 GRAND MARQUIS Article 03-1-1 is being republished in its entirety to update the artwork figures. ISSUE When necessary to service the cooling tan assembly motor, service 1998-2000 model with later model cooling fan assembly motor and a wiring pigtail for compatibility. ACTION Use cooling fan assembly 1W7Z-8C607-AA to service Crown Victoria/Grand Marquis vehicles built 1998 Job 1 through April 4, 2000. Pigtail Connector F8AZ-14370-AA is required for compatibility. Follow Service Procedure. Parts Block OTHER APPLICABLE ARTICLES: 01-10-12 SUPERSEDES:03-1-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Also Under the Provisions Of Emissions Warranty Coverage For 2000 Model Year Only OPERATION DESCRIPTION TIME 030206A Replace Engine Cooling 0.9 Hr. Fan And Install New Wiring Connector DEALER CODING CONDITION BASIC PART NO. CODE 8C607 42 OASIS CODES: 402000 Disclaimer Service Procedure For 1998 - 2000 Model Year Vehicles Built Before April 4, 2000 1. Disconnect battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2549 2. Disconnect fan motor electrical connector. 3. Position lower radiator hose off support bracket and remove wire harness pushpin from fan shroud. 4. Remove the bolt and position aside degas bottle. NOTE THE REMOVAL AND INSTALLATION OF THE FAN AND SHROUD ASSEMBLY WILL REQUIRE A SECOND PERSON TO HOLD THE DEGAS BOTTLE OUT OF THE WAY. 5. Remove (2) bolts and remove fan and shroud assembly. 6. Install lower radiator hose support bracket onto new fan shroud. 7. Install new fan and shroud. Torque to 43.6 Lb-in (5.7 N.m). 8. Reposition the degas bottle and install bolt. Torque to 61.2 - 91.8 Lb-in (8-12 N.m). 9. Remove enough tape from the wire harness starting at fan connector to install fan connector pig tail, then remove wires from the convolute. 10. Cut the existing connector from the engine compartment wiring harness make each cut an inch and a half from the previous cut so that after splicing the wires can be reinstalled into the convolute. 11. Splice the three wires in the pigtail to the engine compartment harness as follows: a. Remove 0.75" (19 mm) of insulation from the wires to be spliced (Figure 1). b. Insert a 2" (50 mm) length of dual wall heat shrink tubing containing hot melt wax on the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2550 c. Splay the strands of the cut wires (Figure 2). d. Twist/mesh the strands of the two wires together (Figure 3). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2551 e. Wrap a 4-5" (100-125 mm) strand of wire tightly around the meshed ends (Figure 4). f. Repeat previous step. g. Solder the tightly wrapped meshed wires (Figure 5). Ensure the splice is thoroughly heated and solder flows completely into the strands. Use rosin core mildly activated (RMA) solder. DO NOT use acid core solder. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2552 h. Center the heat shrink tubing on the splice (Figure 6). i. Heat the entire length of the heat shrink tubing until the hot melt wax appears from both ends of the tubing (Figure 7). 12. Install and tape spliced wires back into convolute. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2553 13. Connect fan motor, position back tower hose onto support bracket, and install wire harness pushpin onto new fan shroud using the lowest locating hole (Figure 8). 14. Connect battery ground cable. Torque to 68.5 Lb-in (9 N.m). 15. Verify fan operation with NGS/WDS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cooling Fan: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cooling Fan: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2558 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cooling Fan: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2559 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure Technical Service Bulletin # 03-2-6 Date: 030203 Cooling System - Cooling Fan Motor Service Procedure Article No. 03-2-6 03/02/03 ^ ELECTRICAL - REVISED COOLING FAN MOTOR AVAILABLE ^ COOLING - REVISED COOLING FAN MOTOR AVAILABLE FORD: 1998-2000 CROWN VICTORIA MERCURY: 1998-2000 GRAND MARQUIS Article 03-1-1 is being republished in its entirety to update the artwork figures. ISSUE When necessary to service the cooling tan assembly motor, service 1998-2000 model with later model cooling fan assembly motor and a wiring pigtail for compatibility. ACTION Use cooling fan assembly 1W7Z-8C607-AA to service Crown Victoria/Grand Marquis vehicles built 1998 Job 1 through April 4, 2000. Pigtail Connector F8AZ-14370-AA is required for compatibility. Follow Service Procedure. Parts Block OTHER APPLICABLE ARTICLES: 01-10-12 SUPERSEDES:03-1-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Also Under the Provisions Of Emissions Warranty Coverage For 2000 Model Year Only OPERATION DESCRIPTION TIME 030206A Replace Engine Cooling 0.9 Hr. Fan And Install New Wiring Connector DEALER CODING CONDITION BASIC PART NO. CODE 8C607 42 OASIS CODES: 402000 Disclaimer Service Procedure For 1998 - 2000 Model Year Vehicles Built Before April 4, 2000 1. Disconnect battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2565 2. Disconnect fan motor electrical connector. 3. Position lower radiator hose off support bracket and remove wire harness pushpin from fan shroud. 4. Remove the bolt and position aside degas bottle. NOTE THE REMOVAL AND INSTALLATION OF THE FAN AND SHROUD ASSEMBLY WILL REQUIRE A SECOND PERSON TO HOLD THE DEGAS BOTTLE OUT OF THE WAY. 5. Remove (2) bolts and remove fan and shroud assembly. 6. Install lower radiator hose support bracket onto new fan shroud. 7. Install new fan and shroud. Torque to 43.6 Lb-in (5.7 N.m). 8. Reposition the degas bottle and install bolt. Torque to 61.2 - 91.8 Lb-in (8-12 N.m). 9. Remove enough tape from the wire harness starting at fan connector to install fan connector pig tail, then remove wires from the convolute. 10. Cut the existing connector from the engine compartment wiring harness make each cut an inch and a half from the previous cut so that after splicing the wires can be reinstalled into the convolute. 11. Splice the three wires in the pigtail to the engine compartment harness as follows: a. Remove 0.75" (19 mm) of insulation from the wires to be spliced (Figure 1). b. Insert a 2" (50 mm) length of dual wall heat shrink tubing containing hot melt wax on the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2566 c. Splay the strands of the cut wires (Figure 2). d. Twist/mesh the strands of the two wires together (Figure 3). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2567 e. Wrap a 4-5" (100-125 mm) strand of wire tightly around the meshed ends (Figure 4). f. Repeat previous step. g. Solder the tightly wrapped meshed wires (Figure 5). Ensure the splice is thoroughly heated and solder flows completely into the strands. Use rosin core mildly activated (RMA) solder. DO NOT use acid core solder. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2568 h. Center the heat shrink tubing on the splice (Figure 6). i. Heat the entire length of the heat shrink tubing until the hot melt wax appears from both ends of the tubing (Figure 7). 12. Install and tape spliced wires back into convolute. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2569 13. Connect fan motor, position back tower hose onto support bracket, and install wire harness pushpin onto new fan shroud using the lowest locating hole (Figure 8). 14. Connect battery ground cable. Torque to 68.5 Lb-in (9 N.m). 15. Verify fan operation with NGS/WDS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <--> [Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > Page 2570 Cooling Fan: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Remove the degas bottle. 2. Disconnect the connector. 3. Remove the two bolts and the fan blade, fan motor and the fan shroud assembly. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2574 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 16-24 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 2588 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the lower intake manifold. 2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor. 3. If necessary, remove the wiring connector. 4. Remove the cylinder head temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Service and Repair Engine Coolant Temperature Sender: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Partially drain the engine cooling system. 2. Remove the water temperature indicator sender unit. 1 Disconnect the electrical connector. 2 Remove the water temperature indicator sender unit. Installation 1. Install the water temperature indicator sender unit. 1 Install the water temperature indicator sender unit. 2 Connect the electrical connector. 2. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan Shroud Screws 45-61 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2603 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2604 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2610 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2611 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2612 Heater Core: Specifications Rubber Suspension Insulator Lube E25Y-19553-A .................................................................................................................................... ESF-M99B112-A Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2613 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2614 Heater Core: Testing and Inspection WARNING: Carbon monoxide is colorless, odorless and dangerous. If it is necessary to operate the engine with the vehicle in a closed area such as a garage, always use an exhaust collector to vent the exhaust gases outside the closed area. Failure to follow these instructions may result in personal injury. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and a new heater core was not required. 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. 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: The heater core inlet hose will become too hot to handle if the system is working correctly. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: - the heater core may have an air pocket. - the heater core may be plugged. - the thermostat may not be working correctly. Heater Core-Pressure Test Use the Radiator/Heater Core Pressure Tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2615 Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core Heater Core: Service and Repair Back Flushing-Heater Core Special Tools 1. WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. when you are sure all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. Once pressure is released, remove the pressure relief cap. 2. Partially drain the cooling system. 3. NOTE: Refer to the cooling system Flush-All Operating Instructions for particular vehicle hook-up. Use cooling system Flush-All, Flush Kit Hardware Package and Drain Kit to backflush the heater core. Use Ford Premium Cooling System Flush F1AZ-19A503-A meeting Ford specification ESR-M14P7A for vehicles filled with Premium Engine Coolant E2FZ-19549-AA or equivalent meeting Ford specification ESE-M97B44-A (green color). Use warm water for vehicles filled with Extended Life Engine Coolant F6AZ-19544-AA or equivalent meeting Ford specification WSS-M97B44-D or DEX-COOL (orange color). 4. Fill the cooling system. See: Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 2618 Heater Core: Service and Repair Removal and Installation REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Remove the plenum chamber. See: Heating and Air Conditioning/Heater Air Plenum Chamber/Service and Repair 2. Remove the screws and the heater core cover. 3. Carefully cut the seal above the heater core inlet and outlet tubes and remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 2619 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2628 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2629 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2635 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2636 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2637 Heater Hose: Service and Repair REMOVAL 1. Drain the radiator. 2. Remove the heater hoses from the heater core. 3. Remove the heater hoses from the engine. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation The engine coolant temperature gauge indicates the engine coolant temperature based on the operating resistance range from the engine coolant temperature sender. If the engine coolant temperature is low, the sender resistance is high. If the engine coolant temperature is high, the sender resistance is low. The engine coolant temperature sender resistance range should be between 9.7 ohms and 74 ohms. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications Radiator: Specifications Radiator Bracket Bolts 80 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2645 Radiator: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Raise the vehicle. 2. Drain the engine cooling system. 3. Remove the fan blade, fan motor and fan shroud assembly. 4. Release three hold downs and remove radiator sight shield. 5. Remove the upper radiator hose from the radiator. 6. Remove the lower radiator hose from the radiator. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2646 7. Remove the bolts and the radiator supports. 8. Remove the bolts and position the A/C condenser core and the transmission oil cooler away from the radiator. 9. Remove the radiator. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2647 1. Follow the removal procedure in reverse order. 2. Fill the cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Pressure Relief Cap Opening Pressure 16 psi Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair Radiator Hose: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Raise the vehicle. 2. Drain the coolant. 3. Remove the lower radiator hose from the radiator. 4. Remove the lower radiator hoses from the oil cooler; (with engine oil cooler). 5. Lower the vehicle. 6. Remove the lower radiator hose from the degas bottle. 7. Remove the lower radiator hose from the oil filter adapter assembly and remove the lower radiator hoses from the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Page 2654 Installation 1. NOTE: Position clamps properly. Follow the removal procedure in reverse order. 2. Fill the cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2664 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2665 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2671 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2672 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2676 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 16-24 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 2688 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the lower intake manifold. 2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor. 3. If necessary, remove the wiring connector. 4. Remove the cylinder head temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Service and Repair Engine Coolant Temperature Sender: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Partially drain the engine cooling system. 2. Remove the water temperature indicator sender unit. 1 Disconnect the electrical connector. 2 Remove the water temperature indicator sender unit. Installation 1. Install the water temperature indicator sender unit. 1 Install the water temperature indicator sender unit. 2 Connect the electrical connector. 2. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation The engine coolant temperature gauge indicates the engine coolant temperature based on the operating resistance range from the engine coolant temperature sender. If the engine coolant temperature is low, the sender resistance is high. If the engine coolant temperature is high, the sender resistance is low. The engine coolant temperature sender resistance range should be between 9.7 ohms and 74 ohms. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Water Thermostat-Start To Open Temperature 192-199 Degrees F Water Thermostat-Full Open Temperature 219 Degrees F Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2698 Thermostat: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Drain coolant below water thermostat. 2. Remove the screw and cover. 3. Remove the bolts from the water hose connection. 4. Position the water hose connection and the upper radiator hose out of the way. 5. Remove the water thermostat and the O-ring from the intake manifold. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2699 1. Follow the removal procedure in reverse order. 2. Fill the cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Water Outlet Adapter 15-22 ft.lb Water Bypass Tube Stud 15-22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump 15-22 ft.lb Water Pump Pulley 15-22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2706 Water Pump: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Drain the coolant. 2. Loosen the bolts. 3. Remove the belt. 4. Remove the bolts and the water pump pulley. 5. Remove the four bolts from the water pump. 6. Remove the water pump. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2707 7. Clean water pump mounting surface. Installation 1. CAUTION: Do not rotate the water pump housing once installed in the engine. Damage to the O-ring can occur, causing the water pump to leak. NOTE: Install a new O-ring seal and lubricate with Ford Premium Engine Coolant E2FZ-19549-AA, F5FZ-19549-CC in Oregon, CXC-10 in Canada or equivalent meeting Ford Specification ESE-M97B44-A. To install, reverse the removal procedure. 2. Fill the cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power Catalytic Converter: Customer Interest CNG Fuel System - Hard Start/DTC's Set/Low Power Article No. 03-20-6 10/13/03 ^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER ^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150 ISSUE Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector performance, resulting from fuel quality. The conditions (in approximate order of their occurrence) include: ^ Loss Of Power At Heavy Load ^ DTC Codes For Lean Fuel ^ Rough Idle ^ Hard Start ^ Plugged Catalytic Converter ^ No Start NOTE THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER. ACTION The root cause of these conditions may be due to either excessive or insufficient carryover compressor oil from the CNG fill station. Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of 10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the injector is opened, but may delay opening or prevent an injector from opening at all. The deposit may increase over time and may further delay the injector opening time. Insufficient oil (less than 10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to open the injector, especially when cold. In either case, the customer may first notice a loss of power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel logic adjustment range for injector pulse width is exceeded. Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector partially or completely shut and cause a hard start or no start. A hard start and temporary rough idle when cold is caused by some of the injectors being marginally functional at the start, and the other injectors becoming functional as they warm up from. engine heat and soften the oil deposit enough to release the stuck pintle. A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely to form injector deposits than either type alone. Vehicles that fill from many stations are more likely to exhibit the conditions. The oil type may also change if a station compressor is serviced or replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has collected in a tank can still remain available to mix even after the compressor oil has been changed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 2717 SERVICE PROCEDURE Different actions are required according to the cause and severity of the conditions exhibited. The actions to correct an insufficient oil situation are different than the actions to correct an excessive oil situation. Customers reporting the conditions listed above may determine their situation by some quick checks on the vehicle. EVIDENCE OF INSUFFICIENT OIL INCLUDES: ^ No oil film on fill station nozzle outlet or vehicle fill receptacle. ^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl. ^ A dry coalescing filter element. EVIDENCE OF EXCESSIVE OIL INCLUDES: ^ Heavy oil film on station nozzle outlet and vehicle fill receptacle. ^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the element. ^ Fully oil-soaked coalescing element. ^ Liquid oil found in fuel tanks or lines opened for other service. Fill stations that derive compressed natural gas from liquefied natural gas should have an oil injection system. The extremely cold temperature of liquefied natural gas literally "freezes out" lubricants and these lubricants need to be replaced after the gas returns to its vapor phase. Customers operating their own fill stations (usually fleet customers) should routinely check that all installed equipment is operating properly and is serviced at the intervals recommended by the component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate filters, and coalescing filters. A fill station may have many filters at different points in the flow stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet, and the dispenser. A particulate filter that becomes clogged will indicate its condition by high differential pressures or reduced total flow. A coalescing filter that is not drained often enough can fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream components with no obvious indication at the filter. A fill station technician draining a pressurized coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble, again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than normal due to poor sealing at the piston rings. A fill station maintenance routine should include recording the oil volume drained from downstream filters. This record can be used to compare the oil volume added to the compressor. This will reveal compressor wear and the associated maintenance requirements due to this wear. Customers who maintain their own vehicles should consider measuring and recording the oil level found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in several vehicles in a short period of time may indicate that a fueling station used by those vehicles requires service to reduce its compressor oil carryover. Fleet customers should inquire about the maintenance practices of the fill stations they use. For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in the fuel does not affect the filter element life, so the element should be replaced at the normal 30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil. It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel injectors to return to their normal function. In some fuel environments it may be necessary to perform this cleaning on a regular basis. NOTE IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3 FOR THE INJECTOR CLEANING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 2718 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power Catalytic Converter: All Technical Service Bulletins CNG Fuel System - Hard Start/DTC's Set/Low Power Article No. 03-20-6 10/13/03 ^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER ^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150 ISSUE Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector performance, resulting from fuel quality. The conditions (in approximate order of their occurrence) include: ^ Loss Of Power At Heavy Load ^ DTC Codes For Lean Fuel ^ Rough Idle ^ Hard Start ^ Plugged Catalytic Converter ^ No Start NOTE THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER. ACTION The root cause of these conditions may be due to either excessive or insufficient carryover compressor oil from the CNG fill station. Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of 10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the injector is opened, but may delay opening or prevent an injector from opening at all. The deposit may increase over time and may further delay the injector opening time. Insufficient oil (less than 10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to open the injector, especially when cold. In either case, the customer may first notice a loss of power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel logic adjustment range for injector pulse width is exceeded. Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector partially or completely shut and cause a hard start or no start. A hard start and temporary rough idle when cold is caused by some of the injectors being marginally functional at the start, and the other injectors becoming functional as they warm up from. engine heat and soften the oil deposit enough to release the stuck pintle. A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely to form injector deposits than either type alone. Vehicles that fill from many stations are more likely to exhibit the conditions. The oil type may also change if a station compressor is serviced or replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has collected in a tank can still remain available to mix even after the compressor oil has been changed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 2724 SERVICE PROCEDURE Different actions are required according to the cause and severity of the conditions exhibited. The actions to correct an insufficient oil situation are different than the actions to correct an excessive oil situation. Customers reporting the conditions listed above may determine their situation by some quick checks on the vehicle. EVIDENCE OF INSUFFICIENT OIL INCLUDES: ^ No oil film on fill station nozzle outlet or vehicle fill receptacle. ^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl. ^ A dry coalescing filter element. EVIDENCE OF EXCESSIVE OIL INCLUDES: ^ Heavy oil film on station nozzle outlet and vehicle fill receptacle. ^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the element. ^ Fully oil-soaked coalescing element. ^ Liquid oil found in fuel tanks or lines opened for other service. Fill stations that derive compressed natural gas from liquefied natural gas should have an oil injection system. The extremely cold temperature of liquefied natural gas literally "freezes out" lubricants and these lubricants need to be replaced after the gas returns to its vapor phase. Customers operating their own fill stations (usually fleet customers) should routinely check that all installed equipment is operating properly and is serviced at the intervals recommended by the component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate filters, and coalescing filters. A fill station may have many filters at different points in the flow stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet, and the dispenser. A particulate filter that becomes clogged will indicate its condition by high differential pressures or reduced total flow. A coalescing filter that is not drained often enough can fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream components with no obvious indication at the filter. A fill station technician draining a pressurized coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble, again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than normal due to poor sealing at the piston rings. A fill station maintenance routine should include recording the oil volume drained from downstream filters. This record can be used to compare the oil volume added to the compressor. This will reveal compressor wear and the associated maintenance requirements due to this wear. Customers who maintain their own vehicles should consider measuring and recording the oil level found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in several vehicles in a short period of time may indicate that a fueling station used by those vehicles requires service to reduce its compressor oil carryover. Fleet customers should inquire about the maintenance practices of the fill stations they use. For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in the fuel does not affect the filter element life, so the element should be replaced at the normal 30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil. It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel injectors to return to their normal function. In some fuel environments it may be necessary to perform this cleaning on a regular basis. NOTE IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3 FOR THE INJECTOR CLEANING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 2725 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2730 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2731 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2732 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2733 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2734 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2735 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2736 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2737 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2738 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2739 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2740 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2741 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2742 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2743 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2744 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2750 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2751 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2752 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2753 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2754 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2755 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2756 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2757 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2758 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2759 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2760 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2761 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2762 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2763 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 2764 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2765 Catalytic Converter: Locations Exhaust System Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2766 Exhaust System Dual Exhaust Catalyst Configuration Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2767 Exhaust System Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2768 Exhaust System Single Exhaust Catalyst Configuration Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2769 Catalytic Converter: Service and Repair Removal 1. Raise and support the vehicle. 2. Disconnect the oxygen sensor connectors. 3. Remove the two nuts. 4. Remove the Three Way Catalytic Converter (TWC). ^ Remove the nuts, bolts, damper and gasket. ^ Remove the TWC. Installation 1. Position the three way catalytic converters and install the two nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2770 2. Install a new gasket, bolts, nuts and damper. 3. Connect the heated oxygen sensor connectors. 4. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Nuts 23-27 Nm (17-20 ft.lb) LH Sequence --- RH Sequence --- Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2774 Exhaust Manifold: Testing and Inspection 1. Place a Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side Exhaust Manifold: Service and Repair Left Side Removal 1. Raise the vehicle. 2. Separate the exhaust at the exhaust manifold. 3. Remove the eight nuts. 4. Remove the exhaust manifold and the gasket. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 2777 Exhaust Manifold: Service and Repair Right Side Removal 1. Raise the vehicle. 2. Separate the exhaust at the exhaust manifold. 3. Disconnect the exhaust gas recirculation tube at the exhaust manifold connector. 4. Remove the eight nuts. ^ Remove the exhaust manifold. ^ Remove the gasket. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Page 2778 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair Exhaust Pipe: Service and Repair For service and repair refer to Muffler; Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the inlet pipe-to-muffler clamp. ^ Remove the clamp nuts. ^ Remove the clamp. 3. NOTE: It may be necessary to heat the inlet pipe-to-muffler joint to ease removal. NOTE: To remove the production muffler and tail pipe assembly, it will be necessary to cut the pipe at a point over the axle. Cut the tailpipe at a point over the axle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2785 4. Remove the tailpipe assembly. ^ Remove the tailpipe from the exhaust hanger insulator. ^ Remove the tailpipe. Installation 1. NOTE: It may be necessary to heat the inlet-to-muffler joint to ease installation. Position the muffler and tailpipe assembly. 2. CAUTION: Do not use oil or grease-based lubricants on insulators which deteriorates the rubber. NOTE: A soap-and-water solution will ease installation of the muffler hangers into the rubber tailpipe hanger insulators. Install the exhaust hanger insulators. 3. Install the tailpipe into the exhaust hanger insulator. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2786 4. Install the muffler to the inlet pipe. ^ Position the clamp. ^ Install the nuts. 5. Install the muffler-to-tailpipe gasket, nuts, and the bolts. 6. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2794 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2795 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2796 Powertrain Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2797 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2798 Powertrain Control Module: Specifications Powertrain Control Module Electrical Connector Bolt 4-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2801 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2802 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2803 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2804 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2805 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2806 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2807 Powertrain Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2808 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2809 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2810 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2811 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2812 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2813 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2814 Powertrain Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2815 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2816 Powertrain Control Module: Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 2819 Powertrain Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 2820 Powertrain Control Module: Removal and Replacement Compressed Natural Gas Vehicle (NGV) Module REMOVAL WARNING - DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. - IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 2821 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 2822 1. To install, reverse the removal procedure. - Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Gasoline REMOVAL 1. Disconnect the battery ground cable. 2. Remove the screw and position the powertrain control module electrical connector out of the way. 3. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 2823 4. Remove the powertrain control module cover. 5. Remove the three pin-type retainers and the under dash sight cover. 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 2827 Fuel Injector Driver Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 2828 Fuel Injector Driver Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 2829 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 2830 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 2836 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 2841 Fuel Injector Driver Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 2842 Fuel Injector Driver Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 2843 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 2844 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page 2848 Fuel Valve Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page 2849 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 2855 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2860 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2871 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2872 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 2878 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 2879 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 2880 Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Bolts 4-5 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 2881 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 2882 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Loosen the clamp and remove the air cleaner outlet tube. 4. Remove the four bolts and the mass air flow sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 2883 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2887 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 16-24 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2894 Crankshaft Position Sensor: Description and Operation The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2895 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the two bolts and position the A/C compressor out of the way. 6. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2896 7. Remove the crankshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 2900 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the lower intake manifold. 2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor. 3. If necessary, remove the wiring connector. 4. Remove the cylinder head temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications Fuel Tank Pressure Sensor: Specifications Fuel Tank Pressure Sensor 55 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications > Page 2904 Fuel Tank Pressure Sensor: Service and Repair NOTE: Perform the Fuel Pressure Release Procedure prior to making any repairs. REMOVAL 1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box. 3. Remove the NGV fuel tank pressure sensor. 1 Disconnect the NGV fuel tank pressure sensor electrical connector. 2 Remove the NGV fuel tank pressure sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. ^ Replace the NGV fuel tank pressure sensor O-ring seal. ^ Lubricate the NGV fuel tank pressure sensor O-ring seal with Super Premium 5W30 engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to help seal and ease the installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Nut 20-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2908 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower intake manifold. 3. Disconnect the electrical connector from the Knock Sensor (KS). 4. Remove the nut and the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2913 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2914 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2915 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2916 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2917 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2918 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2919 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2920 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2921 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2922 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2923 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2924 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2925 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2926 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2927 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2928 Oxygen Sensor: Specifications Heated Oxygen Sensor - Front (HO2S) 36-46 Nm Heated Oxygen Sensor - Rear (HO2S) 36-46 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2929 H02S Location Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2933 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2934 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2935 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2937 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2938 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2939 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2940 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2941 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2943 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2944 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front Oxygen Sensor: Service and Repair Front EGO Sensor Wrench Special Tool(s) REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the right side Heated Oxygen Sensor (HO2S). 3. Disconnect the electrical connector from the left side heated oxygen sensor. 4. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 2947 5. Remove the front heated oxygen sensors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L49-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the heated oxygen sensors prior to installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 2948 Oxygen Sensor: Service and Repair Rear EGO Sensor Wrench Special Tool(s) REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the electrical connector from the rear Heated Oxygen Sensor (HO2S). 4. Remove the rear heated oxygen sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 2949 1. To install, reverse the removal procedure. NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L494AA or equivalent meeting Ford specification ESE-M12A4A to the threads of the heated oxygen sensors prior to installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR 5-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2953 Pressure Feedback Exhaust Sensor: Description and Operation The EGR transducer: ^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube ^ sends an EGR flow rate signal to the powertrain control module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2954 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Disconnect the engine control sensor wiring. 4. Remove the two hoses. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2955 5. Remove the two nuts and the differential pressure feedback EGR valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine appearance cover. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the throttle position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2962 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2963 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Loosen the digital Transmission Range (TR) bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2964 7. Tighten the bolts. 8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR sensor electrical connector. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2965 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2971 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2972 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2973 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2974 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2975 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2977 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2978 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2979 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2980 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2981 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2982 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2983 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR 5-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2988 Pressure Feedback Exhaust Sensor: Description and Operation The EGR transducer: ^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube ^ sends an EGR flow rate signal to the powertrain control module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2989 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Disconnect the engine control sensor wiring. 4. Remove the two hoses. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2990 5. Remove the two nuts and the differential pressure feedback EGR valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3000 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3001 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3007 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3008 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow Sensor: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling High Mounted Stop Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow Sensor: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 3014 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow Sensor: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 3020 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3021 Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Bolts 4-5 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3022 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3023 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Loosen the clamp and remove the air cleaner outlet tube. 4. Remove the four bolts and the mass air flow sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3024 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Specifications Fuel Temperature Sensor: Specifications Fuel Tank Temperature Sensor 40 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Upper) Sensor REMOVAL NOTE: The upper fuel tank temperature sensor is also referred to as fuel tank temperature sensor No.1. 1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box. 3. Remove the upper NGV fuel tank temperature sensor. 1 Disconnect the electrical connector. 2 Remove the fuel tank temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor > Page 3030 Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Lower) Sensor REMOVAL NOTE: The lower fuel tank temperature sensor is also referred to as fuel tank temperature sensor No.2. 1. Carry out the Pressure Relief Fuel Line Venting procedure. 2. Raise and support the vehicle. 3. Remove the lower NGV fuel tank shield upper nuts. 4. Remove the lower NGV fuel tank shield. 1 Remove the nuts. 2 Remove the lower NGV fuel tank shield. 5. Remove the lower NGV fuel tank temperature sensor. 1 Disconnect the lower NGV fuel tank temperature sensor electrical connector. 2 Remove the lower NGV fuel tank temperature sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor > Page 3031 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy ^ Replace the lower NGV fuel tank temperature sensor O-ring seal. ^ Lubricate the lower NGV fuel tank temperature sensor O-ring seal with Super Premium 5W30 engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to help seal and ease the installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement Technical Service Bulletin # 99B03 Date: 990301 Campaign - Inertia Switch Bracket Replacement 99B03 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch Original - March, 1999 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - May, 1999 1998-99 Crown Victoria/Grand Marquis - Inertia Switch IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3040 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3041 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 99B03 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hr. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3042 Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal processing channels. Inertia Bracket Kit: XW7Z-9D379-AA CLAIMS PREPARATION -- Entering using DWE -- Use code information shown below: ^ Program Code - 99B03 ^ Labor Operation - See above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE PROCEDURE 1. Open trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3043 2. Remove carpet pushpins from left inner quarter panel. See Figure 1. 3. Pull carpet away from left inner quarter panel. 4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner quarter panel reinforcement. Refer to Figure 2. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3044 5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an assembly. 6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT disconnect inertia switch electrical connector. 7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes. 8. Measure, mark and drill bottom anti-rotation hole as follows: ^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3. ^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at this location. ^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new location. ^ Using a 25/64 inch drill bit, drill hole at center punched location. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3045 9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4. 10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these locations. 11. Remove inertia switch bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3046 12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure 5. 13. Clean all metal shavings from luggage compartment. 14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft). 15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2 lb-ft). 16. Install wiring harness routing pushpins. 17. Press reset button on inertia switch. Make sure switch is set properly. 18. Reposition carpet back on left inner quarter panel. 19. Install carpet pushpins. 20. Close trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3047 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3048 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3049 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement Technical Service Bulletin # 99B03 Date: 990301 Campaign - Inertia Switch Bracket Replacement 99B03 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch Original - March, 1999 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - May, 1999 1998-99 Crown Victoria/Grand Marquis - Inertia Switch IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3055 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3056 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 99B03 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hr. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3057 Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal processing channels. Inertia Bracket Kit: XW7Z-9D379-AA CLAIMS PREPARATION -- Entering using DWE -- Use code information shown below: ^ Program Code - 99B03 ^ Labor Operation - See above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE PROCEDURE 1. Open trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3058 2. Remove carpet pushpins from left inner quarter panel. See Figure 1. 3. Pull carpet away from left inner quarter panel. 4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner quarter panel reinforcement. Refer to Figure 2. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3059 5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an assembly. 6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT disconnect inertia switch electrical connector. 7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes. 8. Measure, mark and drill bottom anti-rotation hole as follows: ^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3. ^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at this location. ^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new location. ^ Using a 25/64 inch drill bit, drill hole at center punched location. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3060 9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4. 10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these locations. 11. Remove inertia switch bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3061 12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure 5. 13. Clean all metal shavings from luggage compartment. 14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft). 15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2 lb-ft). 16. Install wiring harness routing pushpins. 17. Press reset button on inertia switch. Make sure switch is set properly. 18. Reposition carpet back on left inner quarter panel. 19. Install carpet pushpins. 20. Close trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3062 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3063 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 3064 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Page 3065 Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Screws ............................................................................................................................................................ 1.0 Nm (9 in lbs) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Page 3066 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the luggage compartment door. 3. Disconnect the connector from the inertia fuel shutoff switch. 4. Remove the retaining screws from the inertia fuel shutoff switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine appearance cover. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the throttle position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3074 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3078 Crankshaft Position Sensor: Description and Operation The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3079 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the two bolts and position the A/C compressor out of the way. 6. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3080 7. Remove the crankshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3086 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3087 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3088 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3089 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3090 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3091 Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Functional > Page 3094 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Service Precautions WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Functional > Page 3095 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the steering column lock housing bearing and steering column lock gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing bearing. ^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three o'clock position. Rotate it counterclockwise. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 > Functional > Page 3096 2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install the steering wheel. 4. Install the ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Nut 20-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3100 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower intake manifold. 3. Disconnect the electrical connector from the Knock Sensor (KS). 4. Remove the nut and the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Fuel Rail Pressure 105 - 130 psi Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 3106 Fuel Pressure: Specifications Volume Flow ..................................................................................................................................................... ................................................................. 160 lbs/hr Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed Idle Speed Hot Idle 790-815 rpm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. On gasoline vehicles, remove the engine appearance cover. ^ Loosen the retainer. ^ Remove the cover. 2. Remove the idle air control valve inlet tube. 3. Remove the crankcase ventilation hose. 4. Loosen the clamps and remove the air cleaner outlet tube. NOTE: Gasoline shown, natural gas similar. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3114 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 REMOVAL 1. Release the metal clips. 2. Lift the cover. 3. Remove the Air Cleaner (ACL) element. INSTALLATION 1. To install,reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3123 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Typical Vent Stack Installation NOTE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3124 ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3125 Fuel Pressure Release: Service and Repair Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3126 minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3127 Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3128 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3129 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3130 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3131 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3132 Typical Vent Stack Installation NOTE ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3133 ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3134 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3135 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3136 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3137 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Open 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open as necessary. Disconnect the electrical Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3138 connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Ground Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3139 6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as stuck open. 8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The pressure should be at or near 0 kPa (0 psi). 10. Remove the fuel tank solenoid manual lock-down valve. 11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3140 12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops. 14. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 15. Perform the fuel line venting procedure. 16. Remove the Manual Override Tool from the fuel tank solenoid valve. 17. Install the fuel tank solenoid manual lock~down valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3141 18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Closed 1. Connect the Grounding Cable to the back side of NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3142 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the manual bleed valve on the Fuel Filler Neck Venting Kit. 7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3143 8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 9. Turn in the Manual Override Tool jackscrew until fuel flows. 10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure reading should be at tank pressure. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Vent the fuel tank until the fuel flow stops. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3144 13. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 14. Perform the fuel line venting procedure. 15. Remove the Manual Override Tool from the fuel tank solenoid valve. 16. Install the fuel tank solenoid manual lock-down valve. 17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order 1-3-7-2-6-5-4-8 Coil On Plug Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plugs 20 Nm Spark Plug Gap 1.32-1.42 mm Spark Plug Type AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3156 Spark Plug: Specifications Spark Plugs 20 Nm Spark Plug Gap 1.32-1.42 mm Spark Plug Type AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3157 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................................................... AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3158 Spark Plug: Description and Operation The spark plugs: ^ change a high voltage pulse into a spark which ignites the fuel and air mixture. ^ originally equipped on the vehicle have a platinum-enhanced active electrode for long life. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3159 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil. 2. Remove the spark plugs. NOTE: Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 3. Inspect the spark plugs for a gap bridged. ^ Check for deposit build-up closing the gap between electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 4. Inspect 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3160 5. Inspect for carbon fouling, identified by black, dry, fluffy carbon deposits on insulator tips, exposed shell surfaces and electrodes. This is caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 6. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 7. Inspect for pre-ignition, ^ identified by melted electrodes and possibly a damaged insulator. Metallic deposits on the insulator indicate engine damage, which may be caused by incorrect ignition timing, wrong type of fuel or the installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 8. Inspect for overheating, identified by a white or light gray insulator with small black or gray-brown spots with bluish-burnt appearance of electrodes. This can be caused by engine overheating, the wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3161 ^ Install a new spark plug. 9. Inspect for fused spot deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. 10. Adjust the spark plug gap as required. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart (Part 1 Of 2) Compression Pressure Limit Chart (Part 2 Of 2) The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3165 Compression Check: Testing and Inspection Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Pressure Limit Chart (Part 1 Of 2) Compression Pressure Limit Chart (Part 2 Of 2) Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3166 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3179 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3180 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3186 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3187 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3188 Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Bolts 4-5 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3189 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3190 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Loosen the clamp and remove the air cleaner outlet tube. 4. Remove the four bolts and the mass air flow sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3191 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3195 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 16-24 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3202 Crankshaft Position Sensor: Description and Operation The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3203 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the two bolts and position the A/C compressor out of the way. 6. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3204 7. Remove the crankshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3209 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3210 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3211 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3212 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3213 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3214 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 Data Link Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3217 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3218 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3219 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3220 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3221 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3222 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3227 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3228 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3229 Powertrain Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3230 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3231 Powertrain Control Module: Specifications Powertrain Control Module Electrical Connector Bolt 4-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3234 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3235 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3236 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3237 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3238 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3239 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3240 Powertrain Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3241 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3242 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3243 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3244 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3245 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3246 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3247 Powertrain Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3248 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3249 Powertrain Control Module: Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3252 Powertrain Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3253 Powertrain Control Module: Removal and Replacement Compressed Natural Gas Vehicle (NGV) Module REMOVAL WARNING - DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. - IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3254 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3255 1. To install, reverse the removal procedure. - Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Gasoline REMOVAL 1. Disconnect the battery ground cable. 2. Remove the screw and position the powertrain control module electrical connector out of the way. 3. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3256 4. Remove the powertrain control module cover. 5. Remove the three pin-type retainers and the under dash sight cover. 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3260 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the lower intake manifold. 2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor. 3. If necessary, remove the wiring connector. 4. Remove the cylinder head temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3264 Fuel Injector Driver Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3265 Fuel Injector Driver Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3266 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3267 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications Fuel Tank Pressure Sensor: Specifications Fuel Tank Pressure Sensor 55 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications > Page 3271 Fuel Tank Pressure Sensor: Service and Repair NOTE: Perform the Fuel Pressure Release Procedure prior to making any repairs. REMOVAL 1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box. 3. Remove the NGV fuel tank pressure sensor. 1 Disconnect the NGV fuel tank pressure sensor electrical connector. 2 Remove the NGV fuel tank pressure sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. ^ Replace the NGV fuel tank pressure sensor O-ring seal. ^ Lubricate the NGV fuel tank pressure sensor O-ring seal with Super Premium 5W30 engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to help seal and ease the installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control Valve: Specifications Idle Air Control Valve Bolts 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3275 Idle Air Control Valve: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine appearance cover. 3. Disconnect the electrical connector from the Idle Air Control (IAC) valve. 4. Remove the idle air control valve hose. 5. Remove the two screws and the idle air control valve. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3276 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions Multiplex Communication Network: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3281 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3282 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3283 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3284 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3285 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3286 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3287 Multiplex Communication Network: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3288 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3289 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3290 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3292 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3293 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 Multiplex Communication Network: Electrical Diagrams Diagram 14-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 Diagram 14-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Module Communication Network Multiplex Communication Network: Description and Operation Module Communication Network Principles of Operation The vehicle has two module communication networks. The Standard Corporate Protocol (SCP) communication network, which is an unshielded twisted pair cable (data bus plus, Circuit 914 [TN/OG] and data bus minus, Circuit 915 [PK/LB]) and the International Standards Organization (ISO) 9141 communications network which is a single-wire network(Circuit 70 [LB/W]). Both networks can be connected to New Generation STAR (NGS) Tester by one connector called the Data Link Connector (DLC). This makes diagnosis and testing these systems easier by allowing one smart tester to be able to diagnose and control any module on the two networks from one connector. The DLC can be found under the instrument panel between the steering column and the radio. The ISO 9141 communication network does not permit intermodule communication. When NGS Tester communicates to modules on the ISO 9141 communication network, NGS Tester must ask for all information; the modules cannot initiate communications. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Module Communication Network > Page 3298 The SCP communication network will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or battery positive voltage (B+), or if some but not all termination resistors are lost. Unlike the SCP communication network, the ISO 9141 communication network will not function if the wire is shorted to ground or battery positive voltage (B+). Also, if one of the modules on the ISO 9141 communication network loses power or shorts internally, communications to that module will fail. The Electronic Crash Sensor (ECS) is connected to the ISO 9141 communication network. The ECS controls the deployment of the air bags based on sensor input. The Driver Door Module (DDM) is connected to the SCP communication network. The module controls many functions including power windows, power locks and keyless remote entry. The Lighting Control Module (LCM) is connected to the SCP communication network. The LCM controls both interior and exterior lighting, anti-theft functions and warning chimes. The Electronic Automatic Temperature Control (EATC) module is connected to the SCP communication network. The EATC module controls automatic climate functions that maintain the vehicle at a constant temperature setting. The Powertrain Control Module (PCM) is connected to the SCP communication network. The PCM controls the engine performance, electronic ignition, emission controls and on-board diagnostics. The Natural Gas Vehicle Module (NGVM) calculates fuel level based on inputs from the fuel tank pressure sensor and the fuel tank temperature sensor. The NGVM then provides a voltage signal to the instrument cluster to drive the fuel gauge. The NGVM also has separate injector drivers to run the injectors at the higher operating pressure of natural gas. The NGVM does not perform any calculations for this function; calibration for the injectors is maintained in the Powertrain Control Module (PCM). The anti-lock brake control module is connected to the SCP communication network. The module controls the brake pressure to the four wheels to keep the vehicle under control while braking. The Passive Anti-Theft System (PATS) module is on the SCP communication network. The PATS module communicates with the PCM to disable and start the vehicle based on a signal received from an encoded ignition key signal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Module Communication Network > Page 3299 Multiplex Communication Network: Description and Operation Module Configuration NOTE ^ Newly released modules will require configuration after being installed on the vehicle. All configurable modules will be packaged in a kit which contains a warning label and a multi-language sheet reemphasizing the requirements to configure replacement modules. ^ The Powertrain Control Module (PCM) has to be flash programmed using a flash cable. Customer Driven Preferences There are customer preference items that can or need to be configured on this vehicle. These are items that the customer may or may not want to have enabled. Typically, customer preference items can be toggled on or off by the use of a Ford compatible scan tool. You may need to ask the customer which preferences they had enabled prior to installation of the new module. To carry out the customer configuration process, use a Ford Service Function (FSF) card and the NGS Tester. Refer to the Customer Preference Index for modules on the vehicle that have customer preference items. See: Testing and Inspection/Pinout Values and Diagnostic Parameters/Module Configuration/Customer Preference Index Configure the items as needed with a Ford compatible scan tool. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis Multiplex Communication Network: Flow of Diagnosis Module Communication Network 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery Junction Box (BJB) Fuse 12 (30 A) ^ Wiring harness ^ Loose or corroded connections ^ Anti-lock brake control module ^ Electronic Automatic Temperature Control (EATC) module ^ Passive Anti-Theft System (PATS) module ^ Natural Gas Vehicle Module (NGVM) ^ Electronic Crash Sensor (ECS) ^ Driver Door Module (DDM) ^ Lighting Control Module (LCM) ^ Powertrain Control Module (PCM) 3. If the concern remains after the inspection, connect NGS Tester to the DLC located beneath the instrument panel and select the vehicle to be tested from the NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^ Check that the program card is correctly installed. ^ Check that the correct version of the program card is installed. ^ Check the connections to the vehicle. ^ Check the ignition switch position. If NGS Tester still does not communicate with the vehicle, GO to Pinpoint Test N. 4. GO to Pinpoint Test PC. See: Pinout Values and Diagnostic Parameters/Module Communication Network/System Precheck Module Configuration 1. Visually inspect for obvious signs of electrical damage. Refer to the following chart: VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) Fuse 12 (30 A). ^ Damaged wiring harness ^ Loose or corroded connectors ^ DDM ^ PATS module 2. If the concern remains after inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch is in RUN position. If the NGS Tester still will not communicate with the vehicle, refer to Information Bus. 3. Refer to the Symptom Chart. See: Pinout Values and Diagnostic Parameters/Module Configuration/Symptom Chart Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3302 Multiplex Communication Network: Pinout Values and Diagnostic Parameters Inspection and Verification (Start Here) 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery Junction Box (BJB) Fuse 12 (30 A) ^ Wiring harness ^ Loose or corroded connections ^ Anti-lock brake control module ^ Electronic Automatic Temperature Control (EATC) module ^ Passive Anti-Theft System (PATS) module ^ Natural Gas Vehicle Module (NGVM) ^ Electronic Crash Sensor (ECS) ^ Driver Door Module (DDM) ^ Lighting Control Module (LCM) ^ Powertrain Control Module (PCM) 3. If the concern remains after the inspection, connect NGS Tester to the DLC located beneath the instrument panel and select the vehicle to be tested from the NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^ Check that the program card is correctly installed. ^ Check that the correct version of the program card is installed. ^ Check the connections to the vehicle. ^ Check the ignition switch position. If NGS Tester still does not communicate with the vehicle, GO to Pinpoint Test N. 4. GO to Pinpoint Test PC. See: Module Communication Network/System Precheck Principles of Operation The vehicle has two module communication networks. The Standard Corporate Protocol (SCP) communication network, which is an unshielded twisted pair cable (data bus plus, Circuit 914 [TN/OG] and data bus minus, Circuit 915 [PK/LB]) and the International Standards Organization (ISO) 9141 communications network which is a single-wire network(Circuit 70 [LB/W]). Both networks can be connected to New Generation STAR (NGS) Tester by one connector called the Data Link Connector (DLC). This makes diagnosis and testing these systems easier by allowing one smart tester to be able to diagnose and control any module on the two networks from one connector. The DLC can be found under the instrument panel between the steering column and the radio. The ISO 9141 communication network does not permit intermodule communication. When NGS Tester communicates to modules on the ISO 9141 communication network, NGS Tester must ask for all information; the modules cannot initiate communications. The SCP communication network will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or battery positive voltage (B+), or if some but not all termination resistors are lost. Unlike the SCP communication network, the ISO 9141 communication network will not function if the wire is shorted to ground or battery positive voltage (B+). Also, if one of the modules on the ISO 9141 communication network loses power or shorts internally, communications to that module will Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3303 fail. The Electronic Crash Sensor (ECS) is connected to the ISO 9141 communication network. The ECS controls the deployment of the air bags based on sensor input. The Driver Door Module (DDM) is connected to the SCP communication network. The module controls many functions including power windows, power locks and keyless remote entry. The Lighting Control Module (LCM) is connected to the SCP communication network. The LCM controls both interior and exterior lighting, anti-theft functions and warning chimes. The Electronic Automatic Temperature Control (EATC) module is connected to the SCP communication network. The EATC module controls automatic climate functions that maintain the vehicle at a constant temperature setting. The Powertrain Control Module (PCM) is connected to the SCP communication network. The PCM controls the engine performance, electronic ignition, emission controls and on-board diagnostics. The Natural Gas Vehicle Module (NGVM) calculates fuel level based on inputs from the fuel tank pressure sensor and the fuel tank temperature sensor. The NGVM then provides a voltage signal to the instrument cluster to drive the fuel gauge. The NGVM also has separate injector drivers to run the injectors at the higher operating pressure of natural gas. The NGVM does not perform any calculations for this function; calibration for the injectors is maintained in the Powertrain Control Module (PCM). The anti-lock brake control module is connected to the SCP communication network. The module controls the brake pressure to the four wheels to keep the vehicle under control while braking. The Passive Anti-Theft System (PATS) module is on the SCP communication network. The PATS module communicates with the PCM to disable and start the vehicle based on a signal received from an encoded ignition key signal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3304 PC1 Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Test Notes CAUTION ^ Be careful when probing the fuse junction panel, power distribution box or any connectors. Damage will result to the connector receptacle if the probe or terminal being used is too large. ^ Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: If DTCs are recorded and the symptom is not present when performing the Pinpoint Tests, an intermittent concern may be the cause. Always check for loose connections and corroded terminals. A: Antilock Brake Control Module Doesn't Respond to NGS Tester Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3305 A1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3306 A2 - A3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3307 A4 - A5 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3308 B1 - B2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3309 C1 - C3 D: Natural Gas Veh. Module (NGVM) Doesn't Respond To NGS Tester Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3310 D1 - D2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3311 D3 - D4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3312 D5 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3313 E1 - E2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3314 E3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3315 F1 - F2 G: Powertrain Control Module (PCM) No Response To NGS Tester Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3316 G1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3317 G2 - G3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3318 G4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3319 G5 - G6 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3320 G7 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3321 H1 - H2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3322 H3 I: No Module/Network Communication - ISO 9141 Network Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3323 I1 - I2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3324 I3 - I4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3325 I5 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3326 I6 J: No Module/Network Communication - SCP Network Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3327 J1 - J2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3328 J3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3329 J4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3330 J5 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3331 J6 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3332 J7 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3333 J8 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3334 J9 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3335 J10 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3336 J11 - J12 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3337 J13 - J14 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3338 J15 - J16 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3339 J17 - J18 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3340 J19 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3341 J20 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3342 J21 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3343 J22 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3344 K1 - K2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3345 K3 - K4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3346 Inspection and Verification (Start Here) 1. Visually inspect for obvious signs of electrical damage. Refer to the following chart: VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) Fuse 12 (30 A). ^ Damaged wiring harness ^ Loose or corroded connectors ^ DDM ^ PATS module 2. If the concern remains after inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch is in RUN position. If the NGS Tester still will not communicate with the vehicle, refer to Information Bus. 3. Refer to the Symptom Chart. See: Module Configuration/Symptom Chart Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3347 Principles of Operation NOTE ^ Newly released modules will require configuration after being installed on the vehicle. All configurable modules will be packaged in a kit which contains a warning label and a multi-language sheet reemphasizing the requirements to configure replacement modules. ^ The Powertrain Control Module (PCM) has to be flash programmed using a flash cable. Customer Driven Preferences There are customer preference items that can or need to be configured on this vehicle. These are items that the customer may or may not want to have enabled. Typically, customer preference items can be toggled on or off by the use of a Ford compatible scan tool. You may need to ask the customer which preferences they had enabled prior to installation of the new module. To carry out the customer configuration process, use a Ford Service Function (FSF) card and the NGS Tester. Refer to the Customer Preference Index for modules on the vehicle that have customer preference items. See: Module Configuration/Customer Preference Index Configure the items as needed with a Ford compatible scan tool. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3348 A1 Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 3349 Multiplex Communication Network: Service and Repair Heat Gun Or Equivalent Special Tool(s) 1. Disconnect the battery ground cable. 2. Strip the wires. 3. Solder the wires. 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. NOTE: Use rosin core mildly activated (RMA) solder, not acid core solder. 4. Bend the wires back in a straight line. NOTE: Wait for the solder to cool before moving the wires. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 3350 5. Position the (A) heat shrink tube over the (B) wire repair. ^ Overlap the heat shrink tube on both wires. 6. Use Heat Gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Nut 20-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3354 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower intake manifold. 3. Disconnect the electrical connector from the Knock Sensor (KS). 4. Remove the nut and the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 3360 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3365 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3366 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3367 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3368 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3369 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3370 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3371 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3372 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3373 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3374 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3375 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3376 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3377 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3378 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3379 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3380 Oxygen Sensor: Specifications Heated Oxygen Sensor - Front (HO2S) 36-46 Nm Heated Oxygen Sensor - Rear (HO2S) 36-46 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3381 H02S Location Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front Oxygen Sensor: Service and Repair Front EGO Sensor Wrench Special Tool(s) REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the right side Heated Oxygen Sensor (HO2S). 3. Disconnect the electrical connector from the left side heated oxygen sensor. 4. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3399 5. Remove the front heated oxygen sensors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L49-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the heated oxygen sensors prior to installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3400 Oxygen Sensor: Service and Repair Rear EGO Sensor Wrench Special Tool(s) REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the electrical connector from the rear Heated Oxygen Sensor (HO2S). 4. Remove the rear heated oxygen sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3401 1. To install, reverse the removal procedure. NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L494AA or equivalent meeting Ford specification ESE-M12A4A to the threads of the heated oxygen sensors prior to installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR 5-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3405 Pressure Feedback Exhaust Sensor: Description and Operation The EGR transducer: ^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube ^ sends an EGR flow rate signal to the powertrain control module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3406 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Disconnect the engine control sensor wiring. 4. Remove the two hoses. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3407 5. Remove the two nuts and the differential pressure feedback EGR valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3413 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3414 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3415 Powertrain Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3416 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3417 Powertrain Control Module: Specifications Powertrain Control Module Electrical Connector Bolt 4-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 Powertrain Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3430 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3431 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3432 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3433 Powertrain Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3434 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3435 Powertrain Control Module: Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3438 Powertrain Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3439 Powertrain Control Module: Removal and Replacement Compressed Natural Gas Vehicle (NGV) Module REMOVAL WARNING - DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. - IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3440 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3441 1. To install, reverse the removal procedure. - Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Gasoline REMOVAL 1. Disconnect the battery ground cable. 2. Remove the screw and position the powertrain control module electrical connector out of the way. 3. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3442 4. Remove the powertrain control module cover. 5. Remove the three pin-type retainers and the under dash sight cover. 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3446 Fuel Injector Driver Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3447 Fuel Injector Driver Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3448 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3449 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 3455 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3465 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3466 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 3472 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 3473 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3474 Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Bolts 4-5 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3475 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3476 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Loosen the clamp and remove the air cleaner outlet tube. 4. Remove the four bolts and the mass air flow sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3477 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3481 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 16-24 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3488 Crankshaft Position Sensor: Description and Operation The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3489 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the two bolts and position the A/C compressor out of the way. 6. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3490 7. Remove the crankshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3494 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the lower intake manifold. 2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor. 3. If necessary, remove the wiring connector. 4. Remove the cylinder head temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications Fuel Tank Pressure Sensor: Specifications Fuel Tank Pressure Sensor 55 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications > Page 3498 Fuel Tank Pressure Sensor: Service and Repair NOTE: Perform the Fuel Pressure Release Procedure prior to making any repairs. REMOVAL 1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box. 3. Remove the NGV fuel tank pressure sensor. 1 Disconnect the NGV fuel tank pressure sensor electrical connector. 2 Remove the NGV fuel tank pressure sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. ^ Replace the NGV fuel tank pressure sensor O-ring seal. ^ Lubricate the NGV fuel tank pressure sensor O-ring seal with Super Premium 5W30 engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to help seal and ease the installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Nut 20-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3502 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower intake manifold. 3. Disconnect the electrical connector from the Knock Sensor (KS). 4. Remove the nut and the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3507 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3508 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3509 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3510 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3511 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3512 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3513 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3514 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3515 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3516 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3517 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3518 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3519 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3520 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3521 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3522 Oxygen Sensor: Specifications Heated Oxygen Sensor - Front (HO2S) 36-46 Nm Heated Oxygen Sensor - Rear (HO2S) 36-46 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3523 H02S Location Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3526 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3527 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3528 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3529 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3530 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3531 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3532 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3533 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3534 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3535 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3536 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3537 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3538 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front Oxygen Sensor: Service and Repair Front EGO Sensor Wrench Special Tool(s) REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the right side Heated Oxygen Sensor (HO2S). 3. Disconnect the electrical connector from the left side heated oxygen sensor. 4. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3541 5. Remove the front heated oxygen sensors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L49-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the heated oxygen sensors prior to installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3542 Oxygen Sensor: Service and Repair Rear EGO Sensor Wrench Special Tool(s) REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the electrical connector from the rear Heated Oxygen Sensor (HO2S). 4. Remove the rear heated oxygen sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3543 1. To install, reverse the removal procedure. NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L494AA or equivalent meeting Ford specification ESE-M12A4A to the threads of the heated oxygen sensors prior to installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR 5-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3547 Pressure Feedback Exhaust Sensor: Description and Operation The EGR transducer: ^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube ^ sends an EGR flow rate signal to the powertrain control module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3548 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Disconnect the engine control sensor wiring. 4. Remove the two hoses. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3549 5. Remove the two nuts and the differential pressure feedback EGR valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine appearance cover. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the throttle position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3556 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3557 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Loosen the digital Transmission Range (TR) bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3558 7. Tighten the bolts. 8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR sensor electrical connector. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3559 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3566 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3568 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine appearance cover. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the throttle position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3584 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3585 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Loosen the digital Transmission Range (TR) bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3586 7. Tighten the bolts. 8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR sensor electrical connector. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3587 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3593 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3594 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3595 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3596 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3597 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3598 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3599 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3600 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3601 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3602 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3603 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3604 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3605 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power Catalytic Converter: Customer Interest CNG Fuel System - Hard Start/DTC's Set/Low Power Article No. 03-20-6 10/13/03 ^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER ^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150 ISSUE Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector performance, resulting from fuel quality. The conditions (in approximate order of their occurrence) include: ^ Loss Of Power At Heavy Load ^ DTC Codes For Lean Fuel ^ Rough Idle ^ Hard Start ^ Plugged Catalytic Converter ^ No Start NOTE THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER. ACTION The root cause of these conditions may be due to either excessive or insufficient carryover compressor oil from the CNG fill station. Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of 10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the injector is opened, but may delay opening or prevent an injector from opening at all. The deposit may increase over time and may further delay the injector opening time. Insufficient oil (less than 10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to open the injector, especially when cold. In either case, the customer may first notice a loss of power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel logic adjustment range for injector pulse width is exceeded. Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector partially or completely shut and cause a hard start or no start. A hard start and temporary rough idle when cold is caused by some of the injectors being marginally functional at the start, and the other injectors becoming functional as they warm up from. engine heat and soften the oil deposit enough to release the stuck pintle. A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely to form injector deposits than either type alone. Vehicles that fill from many stations are more likely to exhibit the conditions. The oil type may also change if a station compressor is serviced or replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has collected in a tank can still remain available to mix even after the compressor oil has been changed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 3615 SERVICE PROCEDURE Different actions are required according to the cause and severity of the conditions exhibited. The actions to correct an insufficient oil situation are different than the actions to correct an excessive oil situation. Customers reporting the conditions listed above may determine their situation by some quick checks on the vehicle. EVIDENCE OF INSUFFICIENT OIL INCLUDES: ^ No oil film on fill station nozzle outlet or vehicle fill receptacle. ^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl. ^ A dry coalescing filter element. EVIDENCE OF EXCESSIVE OIL INCLUDES: ^ Heavy oil film on station nozzle outlet and vehicle fill receptacle. ^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the element. ^ Fully oil-soaked coalescing element. ^ Liquid oil found in fuel tanks or lines opened for other service. Fill stations that derive compressed natural gas from liquefied natural gas should have an oil injection system. The extremely cold temperature of liquefied natural gas literally "freezes out" lubricants and these lubricants need to be replaced after the gas returns to its vapor phase. Customers operating their own fill stations (usually fleet customers) should routinely check that all installed equipment is operating properly and is serviced at the intervals recommended by the component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate filters, and coalescing filters. A fill station may have many filters at different points in the flow stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet, and the dispenser. A particulate filter that becomes clogged will indicate its condition by high differential pressures or reduced total flow. A coalescing filter that is not drained often enough can fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream components with no obvious indication at the filter. A fill station technician draining a pressurized coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble, again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than normal due to poor sealing at the piston rings. A fill station maintenance routine should include recording the oil volume drained from downstream filters. This record can be used to compare the oil volume added to the compressor. This will reveal compressor wear and the associated maintenance requirements due to this wear. Customers who maintain their own vehicles should consider measuring and recording the oil level found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in several vehicles in a short period of time may indicate that a fueling station used by those vehicles requires service to reduce its compressor oil carryover. Fleet customers should inquire about the maintenance practices of the fill stations they use. For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in the fuel does not affect the filter element life, so the element should be replaced at the normal 30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil. It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel injectors to return to their normal function. In some fuel environments it may be necessary to perform this cleaning on a regular basis. NOTE IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3 FOR THE INJECTOR CLEANING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 3616 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power Catalytic Converter: All Technical Service Bulletins CNG Fuel System - Hard Start/DTC's Set/Low Power Article No. 03-20-6 10/13/03 ^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER ^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150 ISSUE Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector performance, resulting from fuel quality. The conditions (in approximate order of their occurrence) include: ^ Loss Of Power At Heavy Load ^ DTC Codes For Lean Fuel ^ Rough Idle ^ Hard Start ^ Plugged Catalytic Converter ^ No Start NOTE THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER. ACTION The root cause of these conditions may be due to either excessive or insufficient carryover compressor oil from the CNG fill station. Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of 10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the injector is opened, but may delay opening or prevent an injector from opening at all. The deposit may increase over time and may further delay the injector opening time. Insufficient oil (less than 10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to open the injector, especially when cold. In either case, the customer may first notice a loss of power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel logic adjustment range for injector pulse width is exceeded. Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector partially or completely shut and cause a hard start or no start. A hard start and temporary rough idle when cold is caused by some of the injectors being marginally functional at the start, and the other injectors becoming functional as they warm up from. engine heat and soften the oil deposit enough to release the stuck pintle. A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely to form injector deposits than either type alone. Vehicles that fill from many stations are more likely to exhibit the conditions. The oil type may also change if a station compressor is serviced or replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has collected in a tank can still remain available to mix even after the compressor oil has been changed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 3622 SERVICE PROCEDURE Different actions are required according to the cause and severity of the conditions exhibited. The actions to correct an insufficient oil situation are different than the actions to correct an excessive oil situation. Customers reporting the conditions listed above may determine their situation by some quick checks on the vehicle. EVIDENCE OF INSUFFICIENT OIL INCLUDES: ^ No oil film on fill station nozzle outlet or vehicle fill receptacle. ^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl. ^ A dry coalescing filter element. EVIDENCE OF EXCESSIVE OIL INCLUDES: ^ Heavy oil film on station nozzle outlet and vehicle fill receptacle. ^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the element. ^ Fully oil-soaked coalescing element. ^ Liquid oil found in fuel tanks or lines opened for other service. Fill stations that derive compressed natural gas from liquefied natural gas should have an oil injection system. The extremely cold temperature of liquefied natural gas literally "freezes out" lubricants and these lubricants need to be replaced after the gas returns to its vapor phase. Customers operating their own fill stations (usually fleet customers) should routinely check that all installed equipment is operating properly and is serviced at the intervals recommended by the component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate filters, and coalescing filters. A fill station may have many filters at different points in the flow stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet, and the dispenser. A particulate filter that becomes clogged will indicate its condition by high differential pressures or reduced total flow. A coalescing filter that is not drained often enough can fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream components with no obvious indication at the filter. A fill station technician draining a pressurized coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble, again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than normal due to poor sealing at the piston rings. A fill station maintenance routine should include recording the oil volume drained from downstream filters. This record can be used to compare the oil volume added to the compressor. This will reveal compressor wear and the associated maintenance requirements due to this wear. Customers who maintain their own vehicles should consider measuring and recording the oil level found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in several vehicles in a short period of time may indicate that a fueling station used by those vehicles requires service to reduce its compressor oil carryover. Fleet customers should inquire about the maintenance practices of the fill stations they use. For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in the fuel does not affect the filter element life, so the element should be replaced at the normal 30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil. It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel injectors to return to their normal function. In some fuel environments it may be necessary to perform this cleaning on a regular basis. NOTE IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3 FOR THE INJECTOR CLEANING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 3623 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3628 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3629 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3630 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3631 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3632 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3633 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3634 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3635 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3636 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3637 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3638 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3639 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3640 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3641 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3642 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3648 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3649 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3650 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3651 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3652 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3653 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3654 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3655 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3656 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3657 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3658 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3659 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3660 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3661 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3662 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3663 Catalytic Converter: Locations Exhaust System Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3664 Exhaust System Dual Exhaust Catalyst Configuration Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3665 Exhaust System Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3666 Exhaust System Single Exhaust Catalyst Configuration Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3667 Catalytic Converter: Service and Repair Removal 1. Raise and support the vehicle. 2. Disconnect the oxygen sensor connectors. 3. Remove the two nuts. 4. Remove the Three Way Catalytic Converter (TWC). ^ Remove the nuts, bolts, damper and gasket. ^ Remove the TWC. Installation 1. Position the three way catalytic converters and install the two nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3668 2. Install a new gasket, bolts, nuts and damper. 3. Connect the heated oxygen sensor connectors. 4. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade Technical Service Bulletin # 02B02 Date: 030301 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3678 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3679 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3680 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3681 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3682 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. Not all CVPI vehicles built in the affected time period are eligible for this program because many are no longer in law enforcement duty. Ford has used motor vehicle and U.S. postal records to purge vehicles known to no longer be currently in law enforcement duty. If you encounter a vehicle currently in law enforcement duty that is not listed in OASIS see below. Also see "FINAL ELIGIBILITY CHECK" below for additional restrictions. VIN ADDITION OF NON-P71 VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY Non-Police Interceptor package Crown Victoria vehicles (P70, P72, P73, P74) currently in law enforcement duty & subjected to risk of high-speed high-energy rear impact collisions may have 02B02 performed at no-charge at the request of a law enforcement official. Documentation of law enforcement use such as a letter on department letterhead with VIN is required. Please call to request the addition to OASIS of a non-P71 Crown Victoria vehicle currently in law enforcement duty. FINAL ELIGIBILITY CHECK AND REMOVAL OF INELIGIBLE VEHICLES FROM OASIS In addition to preliminary eligibility verification through OASIS please verify by visual inspection the vehicle is currently in law enforcement duty. Under 02B02 all CVPI vehicles currently in law enforcement duty can be upgraded at no-charge. Many CVPI vehicles are sold to the secondary market (taxi private use) after retirement from law enforcement duty. Based on vehicle registration data available to Ford some of these secondary market vehicles may inadvertently receive an owner letter. Therefore possession of a letter from Ford does not in itself indicate eligibility for 02B02. CVPI vehicles in the secondary market are not eligible for no-charge upgrades under the terms of program 02B02. If the CVPI is no longer currently used in law enforcement duty and the VIN is active in OASIS submit a claim for VIN closure (see ATTACHMENT II). PLEASE NOTE If requested by your law enforcement fleet customer correct in-stock vehicles before delivery. You must contact the Low Volume Coordination Center at 1-800-248-0186 to arrange for parts if you have an involved vehicle in stock. When calling this number identify Optional Upgrade Program 02B02 and have the VIN of the dealer stock vehicle to be serviced. DEALER-OWNER CONTACT An Online Involved Unit Listing will not be available for this program. Not all CVPI vehicles built in the affected time period are eligible for this program. Ford has used motor vehicle and U.S. postal records to purge vehicles known to no longer be currently in law enforcement duty. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. STATUS OF TECHNICAL SERVICE BULLETIN (TSB) 01-21-14 Optional Upgrade Program 02B02 eliminates the need for TSB 01-21-14. Warranty claims submitted for performing TSB 01-21-14 on or after September 27, 2002 will not be processed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3683 OWNER REFUNDS FOR TSB 01-21-14 Ford Motor Company will only refund owner-paid repairs for TSB 01-21-14 made before September 27, 2002 on CVPI vehicles currently in law enforcement duty. No other requests for refunds including repairs not endorsed by Ford Motor Company will be accepted. Refer to ACESII manual for refund information. Program Code: 02B02 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. RENTAL CARS The use of rental vehicles is not authorized for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS ORDERING INFORMATION LAW ENFORCEMENT VEHICLES: Beginning October 22, 2002 law enforcement fleets using CVPI vehicles currently in law enforcement duty will be asked to register using their Fleet Identification Number (FIN) to allow priority parts ordering. Fleets without web access or FIN codes may register at the Police Interceptor Registration Center via telephone. Eligible fleets may establish a FIN code by calling the Fleet Customer Information Center. Once on the website the fleet representative will input fleet name contact and vehicle information. The fleet representative must also certify he/she agrees to review information on the website. Fleets without web access will be sent information contained on the website. Once the required information is provided an Authorization Number will be generated by the website. The fleet will provide their dealer(s) of choice the Authorization Number which will allow priority ordering of parts. Dealers will then contact the Low Volume Coordination Center and provide the fleets Authorization Number to order parts (up to the authorized quantity). A verification of the Authorization Number will be performed and the parts will be ordered for you by the Program Coordination Center. Fleets who do not register may still order parts through their servicing dealer(s); however priority fulfillment of parts orders will be given to registered fleets. Depending upon law enforcement fleet registrations upgrade kits should arrive at your dealership after October 28, 2002. It is estimated that 10% of total kits required to upgrade CVPI vehicles will be available by October 31, 2002. No kits will be available for law enforcement fleets that choose not to register or for retail purchase and installation until supply exceeds registered law enforcement demand. It is anticipated that parts ordering restrictions will be removed beginning January 2, 2003. Attachment III - Technical Information OVERVIEW This procedure provides details for installation of the following: For all affected vehicles ^ Two (2) rear axle shields ^ One (1) differential cover shield Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3684 ^ Two (2) fuel tank strap shields Additional parts required for 1998 through 2003 model year vehicles ^ Two (2) foam pads onto the evaporative emissions canister ^ Replacement of evaporative emissions canister retainer bolts and J-clips (located along the front edge of the canister) with three (3) rivets SERVICE PROCEDURE 1. Raise the vehicle on a hoist. 2. NOTE: Shields are molded with "LH" and "RH" to ease identification. Install the left and right axle shields being sure to position them so there is clearance between the shield and the stabilizer bar as illustrated. On 1992 to 1997 model year vehicles, be sure the ABS circuit wiring harness is not pinched under the shield and the right side parking brake cable is positioned in the notch molded into the shield. Tighten the clamps to 6 Nm (53 lb-in). See Figures 1 and 2. In some cases, excess weld material on the coil spring seat or stabilizer bar bracket can interfere with clamp installation. If necessary, grind away only enough excess weld material to allow for correct seating of the shield and clamp onto the axle. DO NOT grind the parent metal. 3. CAUTION: Tie straps, which are required for 1998 to 2002 model year vehicles only, have specific heat resistant properties. Use of a tie strap other than what is supplied in the kit can jeopardize the repair. Also, correct orientation of the tie strap is critical to the repair. The head of the tie strap must be positioned on the forward-facing side of the shock mount bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3685 On 1998 to 2002 model year vehicles, install one (1) tie strap on each shield to secure it to the shock absorber lower mount bracket as illustrated. If necessary, use pliers and LIGHT force to engage the locking feature of the tie strap. DO NOT STRETCH THE TIE STRAP UNNECESSARILY. See Figure 3. 4. On 1992 to 1997 model year vehicles, install the supplied convolute over the ABS circuit wiring leading to each rear wheel. Position the convolute so it is up against the grommet as shown in the illustration. Secure with vinyl tape. See Figure 4. 5. CAUTION: Do not loosen or remove more than three (3) differential cover bolts at any one time or a leak may develop. NOTE: If the axle identification tag (all affected model year vehicles) and/or fluid identification tag (2002 to 2003 model year vehicles only) interferes with the installation of the differential cover shield, relocate the tag(s) as necessary to another bolt location on the cover. In some instances, the tag may simply need to be rotated to avoid interference with the shield installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3686 Reposition the axle and/or fluid identification tag as necessary. Hand-tighten the bolt(s) at this time. See Figure 5. 6. Remove and discard the three (3) differential cover bolts located at the 4, 6 and 8 o'clock positions. Position the differential cover shield and press into place. The cover should fit snug over the existing bolts. Install the three (3) new bolts. Tighten all loosened or removed bolts to 45 Nm (33 lb-ft). See Figure 5. Be sure to also tighten the axle tag bolt(s) to specification. 17. CAUTION: The fuel tank strap shields are marked for right and left sides of the vehicle. Be sure to install them in the correct location and so that they are oriented from the outside toward the center of the vehicle. NOTE: Spray the area around the fuel tank and strap brackets with silicone lubricant to assist with shield installation. Use a rubber mallet to lightly tap the shields into position only if necessary. Install the left and right fuel tank strap shields as follows. See Figure 6. a) Insert the shield between the fuel tank and the strap from the outside, pushing it in toward the center of the vehicle. b) Position the long tab up into the strap bracket. c) Secure the push-pin retainers into the mating holes in the strap bracket to secure the shield. d) Visually check to make sure the shield is correctly positioned. Peel the backing off the adhesive strip and, while holding the upper portion against the fuel tank flange, secure the two halves firmly together. NOTE ^ For 1992 to 1997 model year vehicles, the service procedure is complete. Lower the vehicle. ^ For 1998 to 2003 model year vehicles, continue with this procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3687 8. Remove the two (2) evaporative emissions canister retainer bolts from the front edge along the Z-bracket. 9. Using a straightedge, draw a line indicating the centerline connecting the (2) two bolt holes. Then, measuring from the edge of either of the two bolt holes, mark the centerline at 50 mm (2-in), 101 mm (4-in) and at 152 mm (6-in). See Figure 7. 10. CAUTION: DO NOT drill through the trunk floor when drilling the rivet holes. Place a drill stop or an abundance of tape 12 mm (1/2-inch) from the tip of the drill bit. Reinstall one of the removed bolts to hold the canister securely, then drill the three, 5 mm (13/64-inch) rivet holes through the Z-bracket and the evaporative emissions canister mounting flange. See Figure 8. 11. Remove the one (1) bolt and the two (2) evaporative emissions canister retaining nuts and lower the canister off of the studs and disconnect the canister purge valve electrical connector. Discard both removed canister bolts. 12. Remove and discard the two (2) J-nuts from the evaporative emissions canister flange. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3688 13. Using Motorcraft Brake Parts Cleaner or equivalent and a clean shop rag, clean the top surface of the canister. Affix the two (2) self-adhesive foam pads onto the canister in the position shown in the illustration. See Figure 9. 14. Reconnect the canister purge valve, then position the evaporative emissions canister and install the two (2) retaining nuts finger tight. 15. CAUTION: The rivets supplied in the kit provide a high clamp-load and MUST be used. Using rivets other than what is supplied in the kit may jeopardize the repair. NOTE: The kit comes with a total of five (5) rivets. Only three (3) are required for this repair. These rivets are very sturdy and may be difficult to install with a small, hand-held pop rivet installer. The use of a large capacity or air/hydraulic rivet installer is recommended but is not necessary. Install the three (3) rivets, then tighten the two canister retaining nuts to 6 Nm (53 lb-in). 16. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3689 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3690 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3691 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3692 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3693 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3694 Attachment I - S1 OASIS When a customer requests inspection of an Upgrade Kit installation use OASIS to determine eligibility for this inspection program. Only vehicles having previously had the Upgrade Kit installed are eligible for this inspection program. PLEASE NOTE Inspect before delivery all upgraded vehicles in stock with build dates on or before October 21, 2002. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ A part quantity of three (3) [rivets] should be entered on the ACES II claim. OWNER REFUNDS Owner refunds are not applicable for this inspection. RENTAL VEHICLES The use of rental vehicles is not authorized for this inspection. Attachment II - S1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3695 LABOR ALLOWANCES FOR 02B02 INSPECTION Reference the original 02B02 dealer bulletin for first-time Upgrade kit installation labor times and technical instructions. Inspections do not apply to vehicles that have not had 02B02 performed previously. PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels. Effective immediately follow the normal order process for Stock Orders and Interim Orders. For Emergency Orders for the first 30 days following launch, call 1-800-325-5621. After 30 days follow the normal order process for Emergency Orders. NOTE: A part quantity of three (3) [rivets] should be entered on the ACES II claim. ORDER INFORMATION The DOR/COR for this program is 50287. This number identifies parts ordered for this Customer Satisfaction Program through the Special Service Support Center (1-800-325-5621). DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - S1 CERTAIN 1998 THROUGH 2003 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTOR (CVPI) VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY - INSPECTION OF OPTIONAL POLICE INTERCEPTOR PACKAGE UPGRADE KIT INSTALLATION This procedure involves inspecting the evaporative emissions canister mounting modifications to see if they conform to the 02B02 Attachment III technical instructions. Based upon vehicle inspections and a vehicle survey, Ford Motor Company has found that some technicians are not removing the bolts and J-nuts affixing the evaporative emissions canister to the underbody of the trunk as instructed. Specifically, proper installation of the evaporative canister rivets and removal of the original bolts and J-nuts cannot be skipped and must be completed properly to provide the full benefit of the optional upgrade. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3696 Provided here is a check sheet to inspect for proper modification of the evaporative emissions canister mounting. The check sheet will help ensure that Steps 8 through 15 of the original 02B02 upgrade have been followed. Check off each item as you inspect it, then answer whether the original installation was done properly or if corrections were required. If any corrections were done, list them in the space provided. At the end of the entire procedure, sign and date the last page certifying the validity of the installation. Retain this inspection sheet in the dealer's vehicle service file. WARNING! ALL STEPS OF THE ORIGINAL INSTALLATION PROCEDURE MUST BE PERFORMED AS WRITTEN WITHOUT ANY MODIFICATION TO PROVIDE THE FULL BENEFIT OF THE OPTIONAL UPGRADE. REFER TO THE ATTACHMENT III FOUND ON THE PTS WEBSITE TO VIEW VIDEO CLIPS OF CERTAIN REPAIR STEPS. IMPORTANT NOTES CHECKOFF EACH ITEM AS YOU INSPECT IT, THEN ANSWER WHETHER THE ORIGINAL INSTALLATION WAS DONE PROPERLY. IF ANY CORRECTIONS WERE REQUIRED, LIST THEM IN THE SPACE PROVIDED. ANY DISCREPANCIES TO THE 02B02 INSTALLATION PROCEDURES MUST BE CORRECTED. THIS DOCUMENT SHOULD BE SIGNED BY BOTH THE SERVICING TECHNICIAN AND THE SERVICE MANAGER AND BE MAINTAINED IN THE DEALER'S VEHICLE SERVICE FILE, STAPLED TO THE HARD COPY OF THE REPAIR ORDER. HAVE A COPY OF THE ORIGINAL 02B02 ATTACHMENT III AVAILABLE FOR REFERENCE DURING THIS INSPECTION PROCEDURE. 1992 THROUGH 1997 CVPI MODELS ARE NOT INVOLVED IN THIS FOLLOW-UP INSPECTION PROCEDURE BECAUSE EVAPORATIVE EMISSIONS CANISTER MOUNTING MODIFICATIONS ARE NOT PART OF THE UPGRADE KIT FOR THOSE MODEL YEARS. INSPECTION 1. Evaporative Emissions Canister Inspection WARNING: DO NOT LEAVE BOLTS AND J-NUTS IN PLACE. THE RIVETS ARE INTENDED TO REPLACE CANISTER BOLTS AND J-NUTS. THEY ARE NOT UTILIZED TO STRENGTHEN THE MECHANICAL CONNECTION BETWEEN THE Z-BRACKET AND THE EVAPORATIVE EMISSIONS CANISTER MOUNTING FLANGE. USING RIVETS OTHER THAN THE SUPPLIED HIGH CLAMP-LOAD RIVETS CAN JEOPARDIZE THE REPAIR. NOTE: Field audits have revealed portions of this repair are not being performed properly. Listed here are examples of what was found: ^ Bolts and J-nuts still installed - rivets installed (correctly or incorrectly) ^ Bolts and J-nuts still installed - rivets NOT installed ^ Only J-nuts still installed - rivets installed ^ Wrong number of rivets installed ^ Rivets not properly spaced along Z-bracket ^ Rivets installed on wrong Z-bracket flange (securing Z-bracket to floor instead of Z-bracket to evap canister) If the bolts and/or J-nuts are still installed, they must be removed. If the rivets are installed, they will need to be drilled out to allow removal of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3697 J-nuts. Once they are removed, NEW high clamp-load rivets must be installed as outlined in 02B02 Attachment III. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3698 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3699 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3700 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3701 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3702 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3703 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3704 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3705 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade Technical Service Bulletin # 02B02 Date: 030301 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3711 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3712 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3713 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3714 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3715 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. Not all CVPI vehicles built in the affected time period are eligible for this program because many are no longer in law enforcement duty. Ford has used motor vehicle and U.S. postal records to purge vehicles known to no longer be currently in law enforcement duty. If you encounter a vehicle currently in law enforcement duty that is not listed in OASIS see below. Also see "FINAL ELIGIBILITY CHECK" below for additional restrictions. VIN ADDITION OF NON-P71 VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY Non-Police Interceptor package Crown Victoria vehicles (P70, P72, P73, P74) currently in law enforcement duty & subjected to risk of high-speed high-energy rear impact collisions may have 02B02 performed at no-charge at the request of a law enforcement official. Documentation of law enforcement use such as a letter on department letterhead with VIN is required. Please call to request the addition to OASIS of a non-P71 Crown Victoria vehicle currently in law enforcement duty. FINAL ELIGIBILITY CHECK AND REMOVAL OF INELIGIBLE VEHICLES FROM OASIS In addition to preliminary eligibility verification through OASIS please verify by visual inspection the vehicle is currently in law enforcement duty. Under 02B02 all CVPI vehicles currently in law enforcement duty can be upgraded at no-charge. Many CVPI vehicles are sold to the secondary market (taxi private use) after retirement from law enforcement duty. Based on vehicle registration data available to Ford some of these secondary market vehicles may inadvertently receive an owner letter. Therefore possession of a letter from Ford does not in itself indicate eligibility for 02B02. CVPI vehicles in the secondary market are not eligible for no-charge upgrades under the terms of program 02B02. If the CVPI is no longer currently used in law enforcement duty and the VIN is active in OASIS submit a claim for VIN closure (see ATTACHMENT II). PLEASE NOTE If requested by your law enforcement fleet customer correct in-stock vehicles before delivery. You must contact the Low Volume Coordination Center at 1-800-248-0186 to arrange for parts if you have an involved vehicle in stock. When calling this number identify Optional Upgrade Program 02B02 and have the VIN of the dealer stock vehicle to be serviced. DEALER-OWNER CONTACT An Online Involved Unit Listing will not be available for this program. Not all CVPI vehicles built in the affected time period are eligible for this program. Ford has used motor vehicle and U.S. postal records to purge vehicles known to no longer be currently in law enforcement duty. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. STATUS OF TECHNICAL SERVICE BULLETIN (TSB) 01-21-14 Optional Upgrade Program 02B02 eliminates the need for TSB 01-21-14. Warranty claims submitted for performing TSB 01-21-14 on or after September 27, 2002 will not be processed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3716 OWNER REFUNDS FOR TSB 01-21-14 Ford Motor Company will only refund owner-paid repairs for TSB 01-21-14 made before September 27, 2002 on CVPI vehicles currently in law enforcement duty. No other requests for refunds including repairs not endorsed by Ford Motor Company will be accepted. Refer to ACESII manual for refund information. Program Code: 02B02 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. RENTAL CARS The use of rental vehicles is not authorized for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS ORDERING INFORMATION LAW ENFORCEMENT VEHICLES: Beginning October 22, 2002 law enforcement fleets using CVPI vehicles currently in law enforcement duty will be asked to register using their Fleet Identification Number (FIN) to allow priority parts ordering. Fleets without web access or FIN codes may register at the Police Interceptor Registration Center via telephone. Eligible fleets may establish a FIN code by calling the Fleet Customer Information Center. Once on the website the fleet representative will input fleet name contact and vehicle information. The fleet representative must also certify he/she agrees to review information on the website. Fleets without web access will be sent information contained on the website. Once the required information is provided an Authorization Number will be generated by the website. The fleet will provide their dealer(s) of choice the Authorization Number which will allow priority ordering of parts. Dealers will then contact the Low Volume Coordination Center and provide the fleets Authorization Number to order parts (up to the authorized quantity). A verification of the Authorization Number will be performed and the parts will be ordered for you by the Program Coordination Center. Fleets who do not register may still order parts through their servicing dealer(s); however priority fulfillment of parts orders will be given to registered fleets. Depending upon law enforcement fleet registrations upgrade kits should arrive at your dealership after October 28, 2002. It is estimated that 10% of total kits required to upgrade CVPI vehicles will be available by October 31, 2002. No kits will be available for law enforcement fleets that choose not to register or for retail purchase and installation until supply exceeds registered law enforcement demand. It is anticipated that parts ordering restrictions will be removed beginning January 2, 2003. Attachment III - Technical Information OVERVIEW This procedure provides details for installation of the following: For all affected vehicles ^ Two (2) rear axle shields ^ One (1) differential cover shield Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3717 ^ Two (2) fuel tank strap shields Additional parts required for 1998 through 2003 model year vehicles ^ Two (2) foam pads onto the evaporative emissions canister ^ Replacement of evaporative emissions canister retainer bolts and J-clips (located along the front edge of the canister) with three (3) rivets SERVICE PROCEDURE 1. Raise the vehicle on a hoist. 2. NOTE: Shields are molded with "LH" and "RH" to ease identification. Install the left and right axle shields being sure to position them so there is clearance between the shield and the stabilizer bar as illustrated. On 1992 to 1997 model year vehicles, be sure the ABS circuit wiring harness is not pinched under the shield and the right side parking brake cable is positioned in the notch molded into the shield. Tighten the clamps to 6 Nm (53 lb-in). See Figures 1 and 2. In some cases, excess weld material on the coil spring seat or stabilizer bar bracket can interfere with clamp installation. If necessary, grind away only enough excess weld material to allow for correct seating of the shield and clamp onto the axle. DO NOT grind the parent metal. 3. CAUTION: Tie straps, which are required for 1998 to 2002 model year vehicles only, have specific heat resistant properties. Use of a tie strap other than what is supplied in the kit can jeopardize the repair. Also, correct orientation of the tie strap is critical to the repair. The head of the tie strap must be positioned on the forward-facing side of the shock mount bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3718 On 1998 to 2002 model year vehicles, install one (1) tie strap on each shield to secure it to the shock absorber lower mount bracket as illustrated. If necessary, use pliers and LIGHT force to engage the locking feature of the tie strap. DO NOT STRETCH THE TIE STRAP UNNECESSARILY. See Figure 3. 4. On 1992 to 1997 model year vehicles, install the supplied convolute over the ABS circuit wiring leading to each rear wheel. Position the convolute so it is up against the grommet as shown in the illustration. Secure with vinyl tape. See Figure 4. 5. CAUTION: Do not loosen or remove more than three (3) differential cover bolts at any one time or a leak may develop. NOTE: If the axle identification tag (all affected model year vehicles) and/or fluid identification tag (2002 to 2003 model year vehicles only) interferes with the installation of the differential cover shield, relocate the tag(s) as necessary to another bolt location on the cover. In some instances, the tag may simply need to be rotated to avoid interference with the shield installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3719 Reposition the axle and/or fluid identification tag as necessary. Hand-tighten the bolt(s) at this time. See Figure 5. 6. Remove and discard the three (3) differential cover bolts located at the 4, 6 and 8 o'clock positions. Position the differential cover shield and press into place. The cover should fit snug over the existing bolts. Install the three (3) new bolts. Tighten all loosened or removed bolts to 45 Nm (33 lb-ft). See Figure 5. Be sure to also tighten the axle tag bolt(s) to specification. 17. CAUTION: The fuel tank strap shields are marked for right and left sides of the vehicle. Be sure to install them in the correct location and so that they are oriented from the outside toward the center of the vehicle. NOTE: Spray the area around the fuel tank and strap brackets with silicone lubricant to assist with shield installation. Use a rubber mallet to lightly tap the shields into position only if necessary. Install the left and right fuel tank strap shields as follows. See Figure 6. a) Insert the shield between the fuel tank and the strap from the outside, pushing it in toward the center of the vehicle. b) Position the long tab up into the strap bracket. c) Secure the push-pin retainers into the mating holes in the strap bracket to secure the shield. d) Visually check to make sure the shield is correctly positioned. Peel the backing off the adhesive strip and, while holding the upper portion against the fuel tank flange, secure the two halves firmly together. NOTE ^ For 1992 to 1997 model year vehicles, the service procedure is complete. Lower the vehicle. ^ For 1998 to 2003 model year vehicles, continue with this procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3720 8. Remove the two (2) evaporative emissions canister retainer bolts from the front edge along the Z-bracket. 9. Using a straightedge, draw a line indicating the centerline connecting the (2) two bolt holes. Then, measuring from the edge of either of the two bolt holes, mark the centerline at 50 mm (2-in), 101 mm (4-in) and at 152 mm (6-in). See Figure 7. 10. CAUTION: DO NOT drill through the trunk floor when drilling the rivet holes. Place a drill stop or an abundance of tape 12 mm (1/2-inch) from the tip of the drill bit. Reinstall one of the removed bolts to hold the canister securely, then drill the three, 5 mm (13/64-inch) rivet holes through the Z-bracket and the evaporative emissions canister mounting flange. See Figure 8. 11. Remove the one (1) bolt and the two (2) evaporative emissions canister retaining nuts and lower the canister off of the studs and disconnect the canister purge valve electrical connector. Discard both removed canister bolts. 12. Remove and discard the two (2) J-nuts from the evaporative emissions canister flange. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3721 13. Using Motorcraft Brake Parts Cleaner or equivalent and a clean shop rag, clean the top surface of the canister. Affix the two (2) self-adhesive foam pads onto the canister in the position shown in the illustration. See Figure 9. 14. Reconnect the canister purge valve, then position the evaporative emissions canister and install the two (2) retaining nuts finger tight. 15. CAUTION: The rivets supplied in the kit provide a high clamp-load and MUST be used. Using rivets other than what is supplied in the kit may jeopardize the repair. NOTE: The kit comes with a total of five (5) rivets. Only three (3) are required for this repair. These rivets are very sturdy and may be difficult to install with a small, hand-held pop rivet installer. The use of a large capacity or air/hydraulic rivet installer is recommended but is not necessary. Install the three (3) rivets, then tighten the two canister retaining nuts to 6 Nm (53 lb-in). 16. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3722 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3723 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3724 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3725 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3726 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3727 Attachment I - S1 OASIS When a customer requests inspection of an Upgrade Kit installation use OASIS to determine eligibility for this inspection program. Only vehicles having previously had the Upgrade Kit installed are eligible for this inspection program. PLEASE NOTE Inspect before delivery all upgraded vehicles in stock with build dates on or before October 21, 2002. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ A part quantity of three (3) [rivets] should be entered on the ACES II claim. OWNER REFUNDS Owner refunds are not applicable for this inspection. RENTAL VEHICLES The use of rental vehicles is not authorized for this inspection. Attachment II - S1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3728 LABOR ALLOWANCES FOR 02B02 INSPECTION Reference the original 02B02 dealer bulletin for first-time Upgrade kit installation labor times and technical instructions. Inspections do not apply to vehicles that have not had 02B02 performed previously. PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels. Effective immediately follow the normal order process for Stock Orders and Interim Orders. For Emergency Orders for the first 30 days following launch, call 1-800-325-5621. After 30 days follow the normal order process for Emergency Orders. NOTE: A part quantity of three (3) [rivets] should be entered on the ACES II claim. ORDER INFORMATION The DOR/COR for this program is 50287. This number identifies parts ordered for this Customer Satisfaction Program through the Special Service Support Center (1-800-325-5621). DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - S1 CERTAIN 1998 THROUGH 2003 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTOR (CVPI) VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY - INSPECTION OF OPTIONAL POLICE INTERCEPTOR PACKAGE UPGRADE KIT INSTALLATION This procedure involves inspecting the evaporative emissions canister mounting modifications to see if they conform to the 02B02 Attachment III technical instructions. Based upon vehicle inspections and a vehicle survey, Ford Motor Company has found that some technicians are not removing the bolts and J-nuts affixing the evaporative emissions canister to the underbody of the trunk as instructed. Specifically, proper installation of the evaporative canister rivets and removal of the original bolts and J-nuts cannot be skipped and must be completed properly to provide the full benefit of the optional upgrade. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3729 Provided here is a check sheet to inspect for proper modification of the evaporative emissions canister mounting. The check sheet will help ensure that Steps 8 through 15 of the original 02B02 upgrade have been followed. Check off each item as you inspect it, then answer whether the original installation was done properly or if corrections were required. If any corrections were done, list them in the space provided. At the end of the entire procedure, sign and date the last page certifying the validity of the installation. Retain this inspection sheet in the dealer's vehicle service file. WARNING! ALL STEPS OF THE ORIGINAL INSTALLATION PROCEDURE MUST BE PERFORMED AS WRITTEN WITHOUT ANY MODIFICATION TO PROVIDE THE FULL BENEFIT OF THE OPTIONAL UPGRADE. REFER TO THE ATTACHMENT III FOUND ON THE PTS WEBSITE TO VIEW VIDEO CLIPS OF CERTAIN REPAIR STEPS. IMPORTANT NOTES CHECKOFF EACH ITEM AS YOU INSPECT IT, THEN ANSWER WHETHER THE ORIGINAL INSTALLATION WAS DONE PROPERLY. IF ANY CORRECTIONS WERE REQUIRED, LIST THEM IN THE SPACE PROVIDED. ANY DISCREPANCIES TO THE 02B02 INSTALLATION PROCEDURES MUST BE CORRECTED. THIS DOCUMENT SHOULD BE SIGNED BY BOTH THE SERVICING TECHNICIAN AND THE SERVICE MANAGER AND BE MAINTAINED IN THE DEALER'S VEHICLE SERVICE FILE, STAPLED TO THE HARD COPY OF THE REPAIR ORDER. HAVE A COPY OF THE ORIGINAL 02B02 ATTACHMENT III AVAILABLE FOR REFERENCE DURING THIS INSPECTION PROCEDURE. 1992 THROUGH 1997 CVPI MODELS ARE NOT INVOLVED IN THIS FOLLOW-UP INSPECTION PROCEDURE BECAUSE EVAPORATIVE EMISSIONS CANISTER MOUNTING MODIFICATIONS ARE NOT PART OF THE UPGRADE KIT FOR THOSE MODEL YEARS. INSPECTION 1. Evaporative Emissions Canister Inspection WARNING: DO NOT LEAVE BOLTS AND J-NUTS IN PLACE. THE RIVETS ARE INTENDED TO REPLACE CANISTER BOLTS AND J-NUTS. THEY ARE NOT UTILIZED TO STRENGTHEN THE MECHANICAL CONNECTION BETWEEN THE Z-BRACKET AND THE EVAPORATIVE EMISSIONS CANISTER MOUNTING FLANGE. USING RIVETS OTHER THAN THE SUPPLIED HIGH CLAMP-LOAD RIVETS CAN JEOPARDIZE THE REPAIR. NOTE: Field audits have revealed portions of this repair are not being performed properly. Listed here are examples of what was found: ^ Bolts and J-nuts still installed - rivets installed (correctly or incorrectly) ^ Bolts and J-nuts still installed - rivets NOT installed ^ Only J-nuts still installed - rivets installed ^ Wrong number of rivets installed ^ Rivets not properly spaced along Z-bracket ^ Rivets installed on wrong Z-bracket flange (securing Z-bracket to floor instead of Z-bracket to evap canister) If the bolts and/or J-nuts are still installed, they must be removed. If the rivets are installed, they will need to be drilled out to allow removal of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3730 J-nuts. Once they are removed, NEW high clamp-load rivets must be installed as outlined in 02B02 Attachment III. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3731 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3732 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3733 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3734 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3735 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3736 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3737 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3738 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications EGR Electronic Vacuum Regulator Solenoid: Specifications EGR Vacuum Regulator Solenoid Nuts 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 3743 EGR Electronic Vacuum Regulator Solenoid: Description and Operation The EGR vacuum regulator solenoid uses input from the powertrain control module to change the EGR valve operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 3744 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Disconnect the connector. 4. Remove the vacuum hoses. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 3745 5. Remove the two nuts and the solenoid electric vacuum regulator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation EGR Tube: Description and Operation The EGR valve to exhaust manifold tube: ^ connects the exhaust manifold to the EGR valve ^ has two tubes connecting to the EGR transducer for EGR flow monitoring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > EGR Valve - EGR Tube EGR Tube: Service and Repair EGR Valve - EGR Tube REMOVAL 1. Disconnect the differential pressure feedback EGR hoses. 2. Disconnect the EGR tube. 3. Remove the two bolts the EGR valve and the gasket. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > EGR Valve - EGR Tube > Page 3751 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > EGR Valve - EGR Tube > Page 3752 EGR Tube: Service and Repair EGR Valve Tube REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Remove the cables from the intake manifold shield. 4. Remove the bolts and the intake manifold shield. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > EGR Valve - EGR Tube > Page 3753 5. Remove the nut at the EGR valve. 6. Raise the vehicle. 7. Remove the nut at the exhaust manifold. 8. Lower the vehicle. 9. Remove the vacuum lines from the differential pressure feedback valve. 10. Remove the vacuum lines from the tube. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > EGR Valve - EGR Tube > Page 3754 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR Valve Bolts 18-22 Nm EGR Valve to Exhaust Manifold Tube Fittings 35-45 Nm EGR Valve NGV 20 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3758 EGR Valve: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the resonator. 3. Remove the vacuum lines. 4. Remove the cables from the intake manifold shield. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3759 5. Remove the bolts from the intake manifold shield. 6. Remove EGR valve to exhaust manifold tube. 7. Remove the bolts and the EGR valve. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3760 1. To install, reverse the removal procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR 5-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3764 Pressure Feedback Exhaust Sensor: Description and Operation The EGR transducer: ^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube ^ sends an EGR flow rate signal to the powertrain control module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3765 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Disconnect the engine control sensor wiring. 4. Remove the two hoses. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3766 5. Remove the two nuts and the differential pressure feedback EGR valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair REMOVAL 1. Remove the engine appearance cover. 2. Remove the idle air control tube from the air cleaner outlet tube. 3. Remove the crankcase ventilation tube at the air cleaner outlet tube. 4. Remove the crankcase ventilation tube at the valve cover. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 3771 1. To install, reverse the removal procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair Positive Crankcase Ventilation Valve: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Remove the Positive Crankcase Ventilation (PVC) valve from the grommet. 4. Remove the Positive Crankcase Ventilation (PVC) valve from the crankcase vent connector and hose. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Page 3775 5. Remove the crankcase vent connector and hose from the throttle body. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR 5-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3780 Pressure Feedback Exhaust Sensor: Description and Operation The EGR transducer: ^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube ^ sends an EGR flow rate signal to the powertrain control module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3781 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the appearance cover. 2. Loosen the clamp and remove the engine air cleaner tube. 3. Disconnect the engine control sensor wiring. 4. Remove the two hoses. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3782 5. Remove the two nuts and the differential pressure feedback EGR valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Fuel Rail Pressure 105 - 130 psi Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure > Page 3788 Fuel Pressure: Specifications Volume Flow ..................................................................................................................................................... ................................................................. 160 lbs/hr Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3793 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Typical Vent Stack Installation NOTE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3794 ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3795 Fuel Pressure Release: Service and Repair Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3796 minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3797 Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3798 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3799 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3800 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3801 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3802 Typical Vent Stack Installation NOTE ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3803 ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3804 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3805 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3806 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3807 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Open 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open as necessary. Disconnect the electrical Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3808 connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Ground Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3809 6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as stuck open. 8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The pressure should be at or near 0 kPa (0 psi). 10. Remove the fuel tank solenoid manual lock-down valve. 11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3810 12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops. 14. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 15. Perform the fuel line venting procedure. 16. Remove the Manual Override Tool from the fuel tank solenoid valve. 17. Install the fuel tank solenoid manual lock~down valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3811 18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Closed 1. Connect the Grounding Cable to the back side of NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3812 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the manual bleed valve on the Fuel Filler Neck Venting Kit. 7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3813 8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 9. Turn in the Manual Override Tool jackscrew until fuel flows. 10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure reading should be at tank pressure. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Vent the fuel tank until the fuel flow stops. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3814 13. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 14. Perform the fuel line venting procedure. 15. Remove the Manual Override Tool from the fuel tank solenoid valve. 16. Install the fuel tank solenoid manual lock-down valve. 17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed Idle Speed Hot Idle 790-815 rpm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal and Shaft to Dash Panel Nuts 15-20 Nm Accelerator Controls Bracket Bolts 5-7 Nm Accelerator Cable Bracket Bolts 8-12 Nm Accelerator Cable Bracket-to-Inatake Manifold Bolts 15-20 Nm Accelerator Cable Housing to Dash Panel Nuts 3-4 Nm Accelerator Cable Housing to Bracket Screw 8-12 Nm EGR Vent Solenoid-to-Accelerator Bracket 7.6-10.4 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3821 Accelerator Pedal: Description and Operation The throttle is controlled by the accelerator cable which is connected to the accelerator pedal and shaft. ^ The accelerator pedal and shaft should travel smoothly from the idle to the Wide-Open Throttle (WOT) positions. Hesitation on return and/or prevention of return to the idle position must not occur. ^ Surrounding components such as wiring, hoses, sound insulator and floor covering must not contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft. ^ The sliding inner member accelerator cable should not be lubricated and is not serviceable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Flow of Diagnosis Accelerator Pedal: Flow of Diagnosis NOTE: Care should be exercised when carrying out service on or around the accelerator pedal linkage and controls. 1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may cause binding. 3. Inspect the engine idle speed adjustment to ensure correct idle speed specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for excessive wear or damage. 5. If concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3824 Accelerator Pedal: Initial Inspection and Diagnostic Overview NOTE: Care should be exercised when carrying out service on or around the accelerator pedal linkage and controls. 1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may cause binding. 3. Inspect the engine idle speed adjustment to ensure correct idle speed specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for excessive wear or damage. 5. If concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3825 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal and Shaft Accelerator Pedal: Service and Repair Accelerator Pedal and Shaft REMOVAL 1. Remove the accelerator cable from the accelerator pedal and shaft. 2. Remove the nuts and remove the accelerator pedal and shaft. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal and Shaft > Page 3828 Accelerator Pedal: Service and Repair Cable Bracket REMOVAL 1. Remove the front engine appearance cover and the throttle return spring. 2. Disconnect the accelerator cable from the throttle body lever. 3. Remove the screw (cable to bracket) and remove the accelerator cable from the accelerator cable bracket. 4. Remove the speed control cable. 5. Remove the spring. 6. Remove the nuts and remove the EGR vent solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal and Shaft > Page 3829 7. Remove the screws and the nut and remove the accelerator cable bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. On gasoline vehicles, remove the engine appearance cover. ^ Loosen the retainer. ^ Remove the cover. 2. Remove the idle air control valve inlet tube. 3. Remove the crankcase ventilation hose. 4. Loosen the clamps and remove the air cleaner outlet tube. NOTE: Gasoline shown, natural gas similar. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3834 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 REMOVAL 1. Release the metal clips. 2. Lift the cover. 3. Remove the Air Cleaner (ACL) element. INSTALLATION 1. To install,reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3846 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3847 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3853 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3854 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3855 Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Bolts 4-5 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3856 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3857 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Loosen the clamp and remove the air cleaner outlet tube. 4. Remove the four bolts and the mass air flow sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3858 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns Fuel: Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns > Page 3863 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3864 Fuel: Service Precautions CAUTION: This vehicle is designed to use Compressed Natural Gas (CNG) as a motor fuel. Failure to follow all applicable warnings concerning CNG may cause serious engine damage and/or personal injury. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3870 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Typical Vent Stack Installation NOTE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3871 ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3872 Fuel Pressure Release: Service and Repair Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3873 minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3874 Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3875 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3876 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3877 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3878 Fuel Pressure Release: Service and Repair Warning WARNING ^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL INFORMATION. ^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE, AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE. ^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3879 Typical Vent Stack Installation NOTE ^ The following venting procedures must be used when removal of the fuel tanks or fuel tank solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves. ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. ^ The following procedures are based on the fuel tank solenoid valves status. Based on the results of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves normal, stuck open or stuck closed. ^ The pressure relief procedure to be followed depends on the component(s) being serviced, what component(s) may be damaged or inoperative, or at what point in fuel system procedures you are referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on fuel tank solenoid status. ^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids (or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is used either in conjunction with the fuel tank venting procedure to make sure of complete fuel system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines if the quarter-turn valve is closed. ^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid must be installed, as the use of the override tool will destroy the solenoid valve. This procedure must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. ^ The special tools required for these procedures are also available in a kit form that comes with all the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test and Venting Kit, 134-00114. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3880 ^ It is recommended that venting be performed with a vent stack. This is a typical installation only. Any vent stack installation must be approved by local authorities. Fuel Line Venting 1. Disconnect the battery ground cable. 2. Connect the Grounding Cable to the fuel injection supply manifold. 3. Connect the Grounding Cable to the ground rod. 4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold Schrader valve and to the Venting Hose Assembly. NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3881 6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to atmosphere for one minute. NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still registers normal fuel system pressure at this point (95-125 psi). 7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the vehicle. Fuel Tank Venting - Solenoid Valves, Functions Normally 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3882 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two spade terminal ends. 8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical connectors connected. 9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench. 10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as functions normally. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The pressure should be at or near 0 kPa (psi). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3883 13. Remove the fuel tank solenoid manual lock-down valve. 14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel flow stops. 17. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3884 18. Perform the fuel line venting procedure. 19. Remove the Manual Override Tool from the fuel tank solenoid valve. 20. Install the fuel tank solenoid manual lock-down valve. 21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Open 1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection. NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open as necessary. Disconnect the electrical Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3885 connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Ground Cable to the ground rod. 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3886 6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as stuck open. 8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The pressure should be at or near 0 kPa (0 psi). 10. Remove the fuel tank solenoid manual lock-down valve. 11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3887 12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops. 14. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 15. Perform the fuel line venting procedure. 16. Remove the Manual Override Tool from the fuel tank solenoid valve. 17. Install the fuel tank solenoid manual lock~down valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3888 18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the procedure until all affected tanks are vented. Solenoid Valves - Stuck Closed 1. Connect the Grounding Cable to the back side of NOTE ^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting. ^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel tank rack vent box. 2. Connect the Grounding Cable to the ground rod. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3889 3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve. NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to connecting to the fuel filler valve. 4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit. 5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the manual bleed valve on the Fuel Filler Neck Venting Kit. 7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3890 8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented. WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual Override Tool will destroy the solenoid valve. 9. Turn in the Manual Override Tool jackscrew until fuel flows. 10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure reading should be at tank pressure. 11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel tank to vent to atmosphere. Venting may take in excess of one hour. 12. Vent the fuel tank until the fuel flow stops. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3891 13. Close the manual backflow valve on the fuel filler valve when the tank contents have been vented. 14. Perform the fuel line venting procedure. 15. Remove the Manual Override Tool from the fuel tank solenoid valve. 16. Install the fuel tank solenoid manual lock-down valve. 17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the procedure until all affected tanks are vented. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications Fuel Injector Wiring Harness: Specifications Fuel Charging Wiring To Intake Manifold Bolts ............................................................................................................................ 8-12 Nm (71-106 In lbs) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 3896 Fuel Injector Wiring Harness: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Position the power steering pump out of the way. 2. Remove the air cleaner outlet tube. 3. Disconnect the battery ground cable. 4. Remove the mounting arm and pivot shaft. 5. Disconnect the: ^ Idle Air Control (IAC) valve. ^ Throttle Position (TP) sensor. 6. Disconnect the eight ignition coils. 7. Disconnect the eight fuel injector electrical connectors. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 3897 8. On natural gas engines, disconnect the temperature sensor. 9. Disconnect the fuel pressure sensor. 10. On natural gas engines, disconnect the main fuel shutoff solenoid connector. 11. Disconnect the engine bulkhead connectors 12. Disconnect the radio ignition interference capacitor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 3898 13. Disconnect the LH heated oxygen sensor connector and the transmission electrical connector. 14. Disconnect the RH heated oxygen sensor connector. 15. Disconnect the EGR transducer. 16. Disconnect the Evaporative Emission (EVAP) canister purge valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 3899 17. Disconnect the EGR vacuum regulator solenoid 18. Disconnect the connector. 19. Disconnect the A/C cycling switch. 20. Raise the vehicle. 21. Disconnect the Crankshaft Position (CKP) sensor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 3900 22. Disconnect the A/C compressor. 23. Disconnect the: ^ engine oil pressure sensor. ^ Power Steering Pressure (PSP) switch. 24. Lower the vehicle. 25. Separate the fuel charging wiring from the rear of the intake manifold and remove from the vehicle. INSTALLATION 1. Position the fuel charging wiring in the vehicle and attach to the rear of the intake manifold. 2. Raise the vehicle. 3. Connect the: ^ engine oil pressure sensor. ^ power steering pressure switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 3901 4. Connect the A/C compressor. 5. Connect the crankshaft position sensor. 6. Install the power steering pump. 7. Lower the vehicle. 8. Connect the A/C cycling switch. 9. Connect the connector Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 3902 10. Connect the EGR vacuum regulator solenoid. 11. Connect the evaporative emission canister purge valve. 12. Connect the EGR transducer. 13. Connect the RH heated oxygen sensor connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 3903 14. Connect the LH heated oxygen sensor connector and the transmission electrical connectors. 15. Connect the radio ignition interference capacitor 16. Connect the engine bulkhead connectors. 17. Connect the main fuel shut-off solenoid connector. 18. Connect the fuel pressure sensor connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 3904 19. Connect the fuel temperature sensor connector. 20. Connect the eight fuel injector electrical connectors. 21. Connect the eight ignition coils. 22. Connect the: ^ idle air control valve. ^ throttle position sensor. 23. Install the mounting arm and pivot shaft. 24. Connect the battery ground cable. 25. Install the air cleaner outlet tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3908 Fuel Injector Driver Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3909 Fuel Injector Driver Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3910 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3911 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Specifications Fuel Line Coupler: Specifications Fuel Line Tube Nut O-ring Fittings 37 Nm Upper Tank Assembly Vent Line Fittings 37 Nm Fuel Line Tube Nut O-Ring Fittings to Fuel Tank Solenoid Valve fittings 90 Nm Fuel Line Tube Nut O-ring Fittings To Fuel Pressure Regulator Fittings 54 Nm Vapor Vent Box Bolts 9 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Specifications > Page 3915 Fuel Line Coupler: Service and Repair Spring Lock Coupling Disconnect Tool (5/8 Inch) Special Tools(s) DISCONNECT 1. Relieve the fuel system pressure. 2. Remove the fuel tube Clip. 3. Install the Spring Lock Coupling Disconnect Tool. 4. Close and push the Spring Lock Coupling Disconnect Tool into the open side of the cage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Specifications > Page 3916 5. Separate the fitting. 6. Remove the Spring Lock Coupling Disconnect Tool CONNECT 1. Push together the spring lock coupling fittings until the spring engages. NOTE ^ Inspect and clean both coupling ends. ^ Install new O-ring seals. ^ Lubricate the O-ring seals with 5W30 engine oil meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help seal and ease the installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications Fuel Pressure Regulator: Specifications Fuel Pressure Regulator Shield Bolts 10 Nm Fuel Pressure Regulator Mounting Bolts 23 Nm Fuel Pressure Regulator/filter Assembly Mounting Bolts 10 Nm Fuel Pressure Regulator 1/2 Inch Elbow Fitting 82 Nm Fuel Pressure Regulator Coolant Bowl Screw 7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel Charging and Controls Fuel Pressure Regulator: Description and Operation Fuel Charging and Controls The fuel pressure regulator: CAUTION: Use O-rings that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse O-rings. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel Charging and Controls > Page 3922 ^ maintains a constant fuel pressure throughout the fuel system and to the fuel injector. ^ is spring-loaded and operated by the intake manifold vacuum. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel Charging and Controls > Page 3923 Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator - Coalescer/Filter Assembly Natural gas vehicles are equipped with a fuel pressure regulator-coalescer/filter assembly. The coalescer/filter assembly separates, filters and stores any contamination and moisture found in the fuel system, preventing moisture from entering the engine. The filter can be disassembled to service the filter element. The drain plug on the bottom of the housing allows the draining of water that has accumulated in the fuel system. The filter should be drained at regular intervals, such as each oil change. The fuel pressure regulator is a single stage pressure reducing regulator which takes the natural gas from tank pressure of 1,379 to 20,685 kPa (200 to 3,000 psi) and regulates it to engine fuel injector pressure of 724 to 862 kPa (105 to 125 psi). When reducing the pressure, the fuel temperature drops significantly, causing extremely cold temperatures of -177°C (-160°F) that may damage fuel system components as well as causing water vapor present in the fuel to condense and freeze, plugging up the fuel system. Engine coolant is circulated to the fuel pressure regulator to prevent this by warming the fuel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3924 Fuel Pressure Regulator: Service and Repair REMOVAL WARNING ^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM, OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. ^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM COMPONENTS TO AVOID POSSIBLE INJURY. 1. Perform the Pressure Relief-Fuel System. 2. Disconnect the battery ground cable. 3. Raise the vehicle. 4. Remove the bolts and remove the fuel pressure regulator shield. 5. Remove the pressure regulator/filter assembly connections. 1 Remove the fuel line tube nut fittings. 2 Clamp off the fuel pressure regulator heater hoses and disconnect the hose clamps from the pressure regulator. 6. Remove the four bolts securing the pressure regulator/filter assembly to the frame rail and remove the assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3925 7. Remove the fitting from the coalescer/filter to the fuel pressure regulator. 8. Remove the fuel pressure regulator retaining bolts and remove the regulator. 9. To remove the fuel pressure regulator coolant bowl, remove the screw and remove the coolant bowl. INSTALLATION NOTE ^ Install new fuel system O-rings using approved O-rings only. O-rings that are approved for natural gas use are identified with a yellow stripe. ^ Lubricate the fuel system O-ring seals with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help seal and ease the installation. ^ When tightening the fuel lines, a torque wrench adapter must be used with the torque wrench. The use of a torque wrench adapter will alter the effective torque of the torque wrench being used. To correct the effective torque, a torque multiplication conversion must be used. ^ After installation is complete, perform the Fuel System Leak Test procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3926 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Fuel Rail Pressure 105 - 130 psi Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure > Page 3932 Fuel Pressure: Specifications Volume Flow ..................................................................................................................................................... ................................................................. 160 lbs/hr Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page 3936 Fuel Valve Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page 3937 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power Fuel Rail: Customer Interest CNG Fuel System - Hard Start/DTC's Set/Low Power Article No. 03-20-6 10/13/03 ^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER ^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150 ISSUE Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector performance, resulting from fuel quality. The conditions (in approximate order of their occurrence) include: ^ Loss Of Power At Heavy Load ^ DTC Codes For Lean Fuel ^ Rough Idle ^ Hard Start ^ Plugged Catalytic Converter ^ No Start NOTE THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER. ACTION The root cause of these conditions may be due to either excessive or insufficient carryover compressor oil from the CNG fill station. Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of 10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the injector is opened, but may delay opening or prevent an injector from opening at all. The deposit may increase over time and may further delay the injector opening time. Insufficient oil (less than 10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to open the injector, especially when cold. In either case, the customer may first notice a loss of power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel logic adjustment range for injector pulse width is exceeded. Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector partially or completely shut and cause a hard start or no start. A hard start and temporary rough idle when cold is caused by some of the injectors being marginally functional at the start, and the other injectors becoming functional as they warm up from. engine heat and soften the oil deposit enough to release the stuck pintle. A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely to form injector deposits than either type alone. Vehicles that fill from many stations are more likely to exhibit the conditions. The oil type may also change if a station compressor is serviced or replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has collected in a tank can still remain available to mix even after the compressor oil has been changed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 3946 SERVICE PROCEDURE Different actions are required according to the cause and severity of the conditions exhibited. The actions to correct an insufficient oil situation are different than the actions to correct an excessive oil situation. Customers reporting the conditions listed above may determine their situation by some quick checks on the vehicle. EVIDENCE OF INSUFFICIENT OIL INCLUDES: ^ No oil film on fill station nozzle outlet or vehicle fill receptacle. ^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl. ^ A dry coalescing filter element. EVIDENCE OF EXCESSIVE OIL INCLUDES: ^ Heavy oil film on station nozzle outlet and vehicle fill receptacle. ^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the element. ^ Fully oil-soaked coalescing element. ^ Liquid oil found in fuel tanks or lines opened for other service. Fill stations that derive compressed natural gas from liquefied natural gas should have an oil injection system. The extremely cold temperature of liquefied natural gas literally "freezes out" lubricants and these lubricants need to be replaced after the gas returns to its vapor phase. Customers operating their own fill stations (usually fleet customers) should routinely check that all installed equipment is operating properly and is serviced at the intervals recommended by the component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate filters, and coalescing filters. A fill station may have many filters at different points in the flow stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet, and the dispenser. A particulate filter that becomes clogged will indicate its condition by high differential pressures or reduced total flow. A coalescing filter that is not drained often enough can fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream components with no obvious indication at the filter. A fill station technician draining a pressurized coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble, again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than normal due to poor sealing at the piston rings. A fill station maintenance routine should include recording the oil volume drained from downstream filters. This record can be used to compare the oil volume added to the compressor. This will reveal compressor wear and the associated maintenance requirements due to this wear. Customers who maintain their own vehicles should consider measuring and recording the oil level found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in several vehicles in a short period of time may indicate that a fueling station used by those vehicles requires service to reduce its compressor oil carryover. Fleet customers should inquire about the maintenance practices of the fill stations they use. For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in the fuel does not affect the filter element life, so the element should be replaced at the normal 30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil. It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel injectors to return to their normal function. In some fuel environments it may be necessary to perform this cleaning on a regular basis. NOTE IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3 FOR THE INJECTOR CLEANING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 3947 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System Hard Start/DTC's Set/Low Power Fuel Rail: All Technical Service Bulletins CNG Fuel System - Hard Start/DTC's Set/Low Power Article No. 03-20-6 10/13/03 ^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER ^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150 ISSUE Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector performance, resulting from fuel quality. The conditions (in approximate order of their occurrence) include: ^ Loss Of Power At Heavy Load ^ DTC Codes For Lean Fuel ^ Rough Idle ^ Hard Start ^ Plugged Catalytic Converter ^ No Start NOTE THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER. ACTION The root cause of these conditions may be due to either excessive or insufficient carryover compressor oil from the CNG fill station. Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of 10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the injector is opened, but may delay opening or prevent an injector from opening at all. The deposit may increase over time and may further delay the injector opening time. Insufficient oil (less than 10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to open the injector, especially when cold. In either case, the customer may first notice a loss of power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel logic adjustment range for injector pulse width is exceeded. Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector partially or completely shut and cause a hard start or no start. A hard start and temporary rough idle when cold is caused by some of the injectors being marginally functional at the start, and the other injectors becoming functional as they warm up from. engine heat and soften the oil deposit enough to release the stuck pintle. A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely to form injector deposits than either type alone. Vehicles that fill from many stations are more likely to exhibit the conditions. The oil type may also change if a station compressor is serviced or replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has collected in a tank can still remain available to mix even after the compressor oil has been changed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System Hard Start/DTC's Set/Low Power > Page 3953 SERVICE PROCEDURE Different actions are required according to the cause and severity of the conditions exhibited. The actions to correct an insufficient oil situation are different than the actions to correct an excessive oil situation. Customers reporting the conditions listed above may determine their situation by some quick checks on the vehicle. EVIDENCE OF INSUFFICIENT OIL INCLUDES: ^ No oil film on fill station nozzle outlet or vehicle fill receptacle. ^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl. ^ A dry coalescing filter element. EVIDENCE OF EXCESSIVE OIL INCLUDES: ^ Heavy oil film on station nozzle outlet and vehicle fill receptacle. ^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the element. ^ Fully oil-soaked coalescing element. ^ Liquid oil found in fuel tanks or lines opened for other service. Fill stations that derive compressed natural gas from liquefied natural gas should have an oil injection system. The extremely cold temperature of liquefied natural gas literally "freezes out" lubricants and these lubricants need to be replaced after the gas returns to its vapor phase. Customers operating their own fill stations (usually fleet customers) should routinely check that all installed equipment is operating properly and is serviced at the intervals recommended by the component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate filters, and coalescing filters. A fill station may have many filters at different points in the flow stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet, and the dispenser. A particulate filter that becomes clogged will indicate its condition by high differential pressures or reduced total flow. A coalescing filter that is not drained often enough can fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream components with no obvious indication at the filter. A fill station technician draining a pressurized coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble, again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than normal due to poor sealing at the piston rings. A fill station maintenance routine should include recording the oil volume drained from downstream filters. This record can be used to compare the oil volume added to the compressor. This will reveal compressor wear and the associated maintenance requirements due to this wear. Customers who maintain their own vehicles should consider measuring and recording the oil level found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in several vehicles in a short period of time may indicate that a fueling station used by those vehicles requires service to reduce its compressor oil carryover. Fleet customers should inquire about the maintenance practices of the fill stations they use. For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in the fuel does not affect the filter element life, so the element should be replaced at the normal 30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil. It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel injectors to return to their normal function. In some fuel environments it may be necessary to perform this cleaning on a regular basis. NOTE IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3 FOR THE INJECTOR CLEANING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System Hard Start/DTC's Set/Low Power > Page 3954 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3955 Fuel Rail: Specifications Fuel Injection Supply Manifold Temperature Sensor 39-42 Nm Fuel Injection Supply Manifold to Intake Manifold 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3956 Fuel Rail: Description and Operation The fuel injection supply manifold: ^ delivers fuel to the fuel injector. ^ receives fuel from the fuel supply line. ^ provides mounting surfaces for the fuel temperature sensor and the fuel pressure sensor. ^ provides mounting surface for the main fuel shut-off solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3957 Fuel Rail: Testing and Inspection LEAK TEST - FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTORS Special Tool(s) 1. Remove the fuel valve relay from the power distribution box. NOTE: After the vehicle has soaked for several hours, a very slight natural gas smell may emanate from within the intake manifold and intake air system. This is normal, as the fuel injectors leak down from the fuel injection supply manifold to the intake manifold over several hours. 2. Construct jumper wire from 152 mm (6 inches) of 18 gauge wire and two spade terminal ends. 3. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. 4. Remove the jumper wife. 5. Install the fuel valve relay into the power distribution box. 6. Check the spring lock coupling and the fuel injection supply manifold to fuel injector connections for leaks using the Combustible Gas Detector (part of NGV Pressure Test and Venting Kit) 7. If a leak is detected, verify the connection is engaged properly, then retest. 8. If the leak remains, repair as necessary and retest. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3958 Fuel Rail: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Relieve the fuel pressure. 3. Disconnect the fuel lines. 4. Remove the throttle body. 5. On gasoline engines, remove the EGR valve to exhaust manifold tube. 6. Remove the drive belt. 7. Disconnect the fuel temperature sensor connector. 8. Disconnect the fuel pressure sensor connector. 9. Disconnect the connector. 10. Disconnect the main fuel shut-off solenoid connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3959 11. Remove the bolts and the generator mounting bracket. 12. Remove the bolts. 13. Unclip the accelerator cable and the speed control actuator cable from the two crash brackets and position out of the way. 14. Separate the LH heated oxygen sensor and the transmission electrical connector from the bracket at the rear of the cylinder head. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3960 15. Remove the nut-bolt and the wiring bracket 16. Disconnect the vacuum lines and position out of the way. NOTE: On natural gas vehicles, there are no EGR vacuum connections. 17. Disconnect the eight fuel injector electrical connectors. 18. Disconnect the crankcase ventilation tube and position out of the way. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3961 19. On gasoline engines, disconnect the vacuum line. 20. On gasoline engines, disconnect the vacuum line from the Evaporative Emission (EVAP) canister purge valve. 21. On gasoline engines, disconnect the EGR vacuum regulator solenoid. 22. Remove the bolt and the stud. 23. Remove the crash bracket. 24. Remove the studs. 25. Remove the fuel injection supply manifold and the fuel injectors as an assembly. INSTALLATION 1. Lubricate the fuel injector pockets with clean engine oil XO-10W30-QSP or DSP or equivalent meeting Ford specification WSS-MZC153-G, to aid installation. CAUTION: Use O-rings that are made of special fuel resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse O-rings. NOTE: Natural gas fuel injectors are identified by an aqua cap. 2. Install the fuel injection supply manifold and the fuel injectors as an assembly 3. Torque fuel injection supply manifold bolts to specification. 4. Install the studs. 5. Install the crash bracket. 6. Install the bolt and the stud. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3962 7. On gasoline engines, connect the EGR vacuum regulator solenoid. 8. On gasoline engines, connect the vacuum line to the evaporative emission canister purge valve. 9. On gasoline engines, connect the vacuum line. 10. Connect the crankcase ventilation tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3963 11. Connect the eight fuel injector electrical connectors. 12. Connect the vacuum lines. NOTE: On natural gas engines there are no EGR vacuum connections. 13. Install the fuel supply retaining bracket nut and bolt. 14. Attach the LH heated oxygen sensor connector and the transmission electrical connector to the bracket at the rear of the cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3964 15. Clip the accelerator cable and the speed control actuator cable to the two crash brackets. 16. Install the bolts. 17. Install the generator mounting bracket and tighten the bolts. 18. Connect the main fuel shut-off solenoid connector. 19. Connect the connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3965 20. Connect the fuel pressure sensor connector. 21. Connect the fuel temperature sensor connector. 22. Install the drive belt. 23. On gasoline engines, install the EGR valve to exhaust manifold tube. 24. Install the throttle body. 25. Connect the fuel lines. 26. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) > Component Information > Technical Service Bulletins > Customer Interest for Fuel Receptacle (CNG): > 03-11-7 > Jun > 03 > Fuel System (CNG) - Fill Valve Leaks Fuel Receptacle (CNG): Customer Interest Fuel System (CNG) - Fill Valve Leaks Article No. 03-11-7 06/09/03 DRIVEABILITY - CNG - POSSIBLE FUEL LEAK AT FILL VALVE - FILL VALVE SERVICE PART REVISIONS - CNG VEHICLES ONLY FORD: 1996-2003 CROWN VICTORIA Article 03-4-9 is being republished in its entirety to update the Service Part numbers due to a Supplier change. ISSUE On some CNG (Compressed Natural Gas) Crown Victoria vehicles, a possible fuel leak may occur at the fuel fill valve. When replacing the fill valve, the previous practice for these vehicles was to service failed CNG till valves with a flange assembly consisting of a flange, a fill valve, a rubber boot, and a dust cap. That practice needlessly complicated production and service part numbering across different vehicle lines since the same fill valve in different flange assemblies was numbered differently. The bypass feature for CNG fill valves is no longer required due to revisions in service procedures and equipment. A new fill valve supplier has been approved for Crown Victoria. ACTION The previous service part (flange assembly) will be separated into a fill valve, a flange, and a rubber boot. One fill valve with one Part Number will then be used to service many vehicles. Different flanges will be released to service each vehicle. Most repairs will be for the fill valve only and the existing flange and boot can remain installed in the vehicle. A replacement dust cap is provided with each fill valve service part and is also available separately. SERVICE PROCEDURE NOTE THIS SERVICE PROCEDURE SHOULD ONLY BE PERFORMED BY AN AUTHORIZED CNG FUEL SYSTEM TECHNICIAN. NOTE FOLLOW ALL CNG FUEL SYSTEM SAFETY PROCEDURES LISTED IN THE APPROPRIATE WORKSHOP MANUAL Fill Valve Removal: 1. Perform the fuel line venting portion of the Fuel System Pressure Release procedure in Workshop Manual Section 310-00B. (For older vehicles equipped with a manual back flow valve, refer to appropriate Model Year Workshop Manual). 2. Remove rubber boot and four (4) retaining screws behind flange and set aside. 3. Using a backup wrench, remove the fuel line tube nut fitting from the fuel filler valve. 4. Remove the flange retaining nut and discard. NOTE USE A 1-3/8 IN DEEP-WALL SOCKET ON RETAINING NUT. 5. Remove the fuel filler valve from the mounting flange. Fill Valve Installation: NOTE LUBRICATE 0-RING SEAL ON FILL VALVE WITH 5W-30 ENGINE OIL. WHEN TIGHTENING THE FUEL LINES TO THE FILLER VALVE, A TORQUE WRENCH ADAPTOR MUST BE USED. REFER TO WORKSHOP MANUAL SECTION 310-00B. NOTE FUEL TEST LEAK PROCEDURE (REFER TO SECTION 310-00B IN WORK SHOP MANUAL) 1. Remove dust caps and flange retaining nut from new fill valve. 2. Install fuel fill valve in mounting flange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) > Component Information > Technical Service Bulletins > Customer Interest for Fuel Receptacle (CNG): > 03-11-7 > Jun > 03 > Fuel System (CNG) - Fill Valve Leaks > Page 3974 3. Install and torque flange retaining nut to 24-30 N.m (18-22 lb-ft). NOTE USE A 1-1/4 IN OR 32 MM DEEP-WALL SOCKET ON RETAINING NUT. Parts List 4. Install rubber boot over back end of till valve behind flange with bulge facing forward. 5. Install and torque four (4) retaining screws to 2.8-4.0 N.m (25-35 lb-in). 6. Install the fuel line to the fuel filler valve and torque fitting nut to 38-57 N.m (28-42 lb-ft) using a backup wrench. 7. Check for leaks at the fuel line fitting (refer to Workshop Manual). Flange Removal: Remove fill valve (see previous procedure). 1. Remove four (4) bolts holding flange. 2. Retain fill valve dust cap. Flange Installation: 1. Hold flange in fuel fill bucket so four (4) screw holes align with four (4) holes in bucket with sharp end of central depression pointing to the rear. 2. Install four (4) bolts and torque to 2.7-3.3 N.m (25-30 lb-in) with grommet of dust cap under lower front bolt. NOTE USE A 1-3/8 IN DEEP-WALL SOCKET ON BRASS RETAINING NUT. USE 1-1/4 IN OR 32 MM DEEP-WALL SOCKET ON STEEL RETAINING NUT. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-4-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) > Component Information > Technical Service Bulletins > Customer Interest for Fuel Receptacle (CNG): > 03-11-7 > Jun > 03 > Fuel System (CNG) - Fill Valve Leaks > Page 3975 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Receptacle (CNG): > 03-11-7 > Jun > 03 > Fuel System (CNG) - Fill Valve Leaks Fuel Receptacle (CNG): All Technical Service Bulletins Fuel System (CNG) - Fill Valve Leaks Article No. 03-11-7 06/09/03 DRIVEABILITY - CNG - POSSIBLE FUEL LEAK AT FILL VALVE - FILL VALVE SERVICE PART REVISIONS - CNG VEHICLES ONLY FORD: 1996-2003 CROWN VICTORIA Article 03-4-9 is being republished in its entirety to update the Service Part numbers due to a Supplier change. ISSUE On some CNG (Compressed Natural Gas) Crown Victoria vehicles, a possible fuel leak may occur at the fuel fill valve. When replacing the fill valve, the previous practice for these vehicles was to service failed CNG till valves with a flange assembly consisting of a flange, a fill valve, a rubber boot, and a dust cap. That practice needlessly complicated production and service part numbering across different vehicle lines since the same fill valve in different flange assemblies was numbered differently. The bypass feature for CNG fill valves is no longer required due to revisions in service procedures and equipment. A new fill valve supplier has been approved for Crown Victoria. ACTION The previous service part (flange assembly) will be separated into a fill valve, a flange, and a rubber boot. One fill valve with one Part Number will then be used to service many vehicles. Different flanges will be released to service each vehicle. Most repairs will be for the fill valve only and the existing flange and boot can remain installed in the vehicle. A replacement dust cap is provided with each fill valve service part and is also available separately. SERVICE PROCEDURE NOTE THIS SERVICE PROCEDURE SHOULD ONLY BE PERFORMED BY AN AUTHORIZED CNG FUEL SYSTEM TECHNICIAN. NOTE FOLLOW ALL CNG FUEL SYSTEM SAFETY PROCEDURES LISTED IN THE APPROPRIATE WORKSHOP MANUAL Fill Valve Removal: 1. Perform the fuel line venting portion of the Fuel System Pressure Release procedure in Workshop Manual Section 310-00B. (For older vehicles equipped with a manual back flow valve, refer to appropriate Model Year Workshop Manual). 2. Remove rubber boot and four (4) retaining screws behind flange and set aside. 3. Using a backup wrench, remove the fuel line tube nut fitting from the fuel filler valve. 4. Remove the flange retaining nut and discard. NOTE USE A 1-3/8 IN DEEP-WALL SOCKET ON RETAINING NUT. 5. Remove the fuel filler valve from the mounting flange. Fill Valve Installation: NOTE LUBRICATE 0-RING SEAL ON FILL VALVE WITH 5W-30 ENGINE OIL. WHEN TIGHTENING THE FUEL LINES TO THE FILLER VALVE, A TORQUE WRENCH ADAPTOR MUST BE USED. REFER TO WORKSHOP MANUAL SECTION 310-00B. NOTE FUEL TEST LEAK PROCEDURE (REFER TO SECTION 310-00B IN WORK SHOP MANUAL) 1. Remove dust caps and flange retaining nut from new fill valve. 2. Install fuel fill valve in mounting flange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Receptacle (CNG): > 03-11-7 > Jun > 03 > Fuel System (CNG) - Fill Valve Leaks > Page 3981 3. Install and torque flange retaining nut to 24-30 N.m (18-22 lb-ft). NOTE USE A 1-1/4 IN OR 32 MM DEEP-WALL SOCKET ON RETAINING NUT. Parts List 4. Install rubber boot over back end of till valve behind flange with bulge facing forward. 5. Install and torque four (4) retaining screws to 2.8-4.0 N.m (25-35 lb-in). 6. Install the fuel line to the fuel filler valve and torque fitting nut to 38-57 N.m (28-42 lb-ft) using a backup wrench. 7. Check for leaks at the fuel line fitting (refer to Workshop Manual). Flange Removal: Remove fill valve (see previous procedure). 1. Remove four (4) bolts holding flange. 2. Retain fill valve dust cap. Flange Installation: 1. Hold flange in fuel fill bucket so four (4) screw holes align with four (4) holes in bucket with sharp end of central depression pointing to the rear. 2. Install four (4) bolts and torque to 2.7-3.3 N.m (25-30 lb-in) with grommet of dust cap under lower front bolt. NOTE USE A 1-3/8 IN DEEP-WALL SOCKET ON BRASS RETAINING NUT. USE 1-1/4 IN OR 32 MM DEEP-WALL SOCKET ON STEEL RETAINING NUT. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-4-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Receptacle (CNG): > 03-11-7 > Jun > 03 > Fuel System (CNG) - Fill Valve Leaks > Page 3982 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Shut-off Solenoid > Component Information > Description and Operation Fuel Shut-off Solenoid: Description and Operation The fuel shut-off solenoid: ^ is normally closed. ^ opens when the key is in the run or start position. ^ shuts off the fuel supply if the vehicle is shut off or if the inertia fuel shut-off is triggered. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Specifications Fuel Supply Line: Specifications Fuel Line Retainer Bolts 9 Nm Flexible Tube Retaining Nuts 12 Nm Fuel Supply Retaining Bracket Nut and Bolt 20-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > High Pressure Line Fuel Supply Line: Service and Repair High Pressure Line REMOVAL WARNING ^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM, OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. ^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM COMPONENTS TO AVOID POSSIBLE INJURY. 1. Perform the Pressure Relief-Fuel System. 2. Disconnect the battery ground cable. 3. Raise the vehicle. 4. Remove the bolts and remove the pressure regulator shield. 5. Remove the fuel tank fuel line tube nut fitting at the quarter-turn valve and the filler valve fuel line tube nut fitting at the coalescer/filter "T" fitting. 6. Remove the fuel tank fuel outlet line tube nut fitting at tank No.3 solenoid "T" fitting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > High Pressure Line > Page 3991 7. Remove the filler valve fuel line tube nut fitting at the rear of the filler valve. 8. Remove the bolts from the fuel line retainers and remove the high pressure fuel lines. INSTALLATION NOTE ^ Install new fuel system O-rings using approved O-rings only. O-rings that are approved for natural gas use are identified with a yellow stripe. ^ Lubricate the fuel system O-ring seals with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help seal and ease the installation. ^ When tightening the fuel lines, a torque wrench adapter must be used with the torque wrench. The use of a torque wrench adapter will alter the effective torque of the torque wrench being used. To correct the effective torque, a torque multiplication conversion must be used. ^ After installation is complete, perform the Fuel System Leak Test procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > High Pressure Line > Page 3992 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > High Pressure Line > Page 3993 Fuel Supply Line: Service and Repair Low Pressure Line Spring Lock Coupling Disconnect Tool (5/8 Inch) Special Tool(s) REMOVAL WARNING ^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM, OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. ^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM COMPONENTS TO AVOID POSSIBLE INJURY. 1. Perform the Pressure Relief-Fuel System. 2. Disconnect the battery ground cable. 3. Disconnect the fuel line spring lock coupling from the engine fuel supply manifold. 4. Raise the vehicle. 5. Remove the LH dual catalytic converter on dual exhaust systems. 6. Remove the bolts and remove the pressure regulator shield. 7. Remove the low pressure fuel line tube nut fitting from the pressure regulator outlet fitting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > High Pressure Line > Page 3994 8. Remove the fuel line retaining bolts. 9. Remove the fuel line retaining bolt at the frame rail near the engine compartment. Remove the fuel line. INSTALLATION NOTE ^ Install new fuel system O-rings using approved O-rings only. O-rings that are approved for natural gas use are identified with a yellow stripe. ^ Lubricate the fuel system O-ring seals with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help seal and ease the installation. ^ When tightening the fuel lines, a torque wrench adapter must be used with the torque wrench. The use of a torque wrench adapter will alter the effective torque of the torque wrench being used. To correct the effective torque, a torque multiplication conversion must be used. ^ After installation is complete, perform the Fuel System Leak Test procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > High Pressure Line > Page 3995 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel System Manual Control Valve (CNG) > Component Information > Service and Repair Fuel System Manual Control Valve (CNG): Service and Repair REMOVAL WARNING ^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM, OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. ^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM COMPONENTS TO AVOID POSSIBLE INJURY. 1. Perform the Pressure Relief-Fuel System. 2. Disconnect the battery ground cable. 3. Raise the vehicle. 4. Remove the bolts and remove the fuel pressure regulator shield. 5. Slowly loosen the fuel line tube nuts to allow residual pressure to vent. Remove the tube nuts from the quarter-turn valve fittings. 6. Remove the retaining clip and remove the quarter-turn valve. INSTALLATION NOTE ^ Install new fuel system O-rings using approved O-rings only. O-rings that are approved for natural gas use are identified with a yellow stripe. ^ Lubricate the fuel system O-ring seals with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help seal and ease the installation. ^ When tightening the fuel lines, a torque wrench adapter must be used with the torque wrench. The use of a torque wrench adapter will alter the effective torque of the torque wrench being used. To correct the effective torque, a torque multiplication conversion must be used. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel System Manual Control Valve (CNG) > Component Information > Service and Repair > Page 3999 ^ After installation is complete, perform the fuel system leak test procedure. 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Specifications Fuel Filler Hose: Specifications Fuel Filler Valve to Body Screws 3 Nm Fuel Filler Valve Outlet Fittings 27 Nm Fuel Filler Manual Backflow Valve 9 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Filler Valve Fuel Filler Hose: Service and Repair Fuel Filler Valve REMOVAL WARNING ^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM, OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. ^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM COMPONENTS TO AVOID POSSIBLE INJURY. 1. Perform the Pressure Relief- Fuel System. 2. Disconnect the battery ground cable. 3. Remove the four screws from the protective boot and position aside. 4. Using a backup wrench, remove the fuel line tube nut fitting from the fuel filler valve. 5. Remove the fuel filler valve retaining bolts and remove the fuel filler valve. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Filler Valve > Page 4006 1. To install, reverse the removal procedure. NOTE ^ Install new fuel system O-ring seals with approved O-rings only. O-rings that are approved for natural gas use are identified with a yellow stripe. ^ Lubricate the fuel system O-ring seals with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help seal and ease the installation. ^ When tightening the fuel lines, a torque wrench adapter must be used with the torque wrench. The use of a torque wrench adapter will alter the effective torque of the torque wrench being used. To correct the effective torque, a torque multiplication conversion must be used. ^ After installation is complete, perform the Fuel System Leak Test procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Filler Valve > Page 4007 Fuel Filler Hose: Service and Repair Fuel Filler Valve Filter Filter Remover/Installer Tool Special Tool(s) REMOVAL 1. Remove the fuel filler valve. 2. Position the fuel filler valve in a vise. 3. Remove the fitting from the fuel filler valve. 4. Using the Filter Remover/Installer Tool 134-OO115 (part of NGV pressure and venting kit 134-00114), turn the fuel filler valve filter counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. NOTE: After installation is complete, perform the Fuel System Leak Test procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair Fuel Tank Mounting Straps: Service and Repair REMOVAL 1. Perform Pressure Relief-Fuel System. WARNING ^ DO NOT MODIFY THE FUEL SYSTEM CONFIGURATION OR COMPONENTS OR INSTALL NEW COMPONENTS WITH PARTS NOT SPECIFICALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIFICALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION FOR THE THIS VEHICLE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY OR PROPERTY DAMAGE. ^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM, OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. ^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM COMPONENTS TO AVOID POSSIBLE INJURY. NOTE: The support straps are part of the fuel rack assembly. The fuel tanks can be removed for service, but a new fuel rack must be installed if there is damage to the support straps or the rack assembly itself. 2. Remove the upper or lower fuel tank rack assembly as required. 3. On upper fuel tank rack assemblies, remove the vapor vent box. 4. On both upper and lower fuel tank rack assemblies, remove the fuel/vent lines as necessary. 5. Remove the bolts securing the straps together. Swing the straps outward on their hinges to access the fuel tanks. NOTE: If the fuel tanks are going to be re-used, mark their location relative to the support straps with a grease pencil to insure proper alignment upon installation. 6. On the lower rack assembly, remove the two bolts securing the support straps together. Swing the support strap up on the hinges to gain access to the fuel tanks. NOTE: If the fuel tanks are going to be re-used, mark their location relative with the support straps with a grease pencil to insure proper alignment upon installation. 7. Remove the solenoid valves if necessary to remove the fuel tanks. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Page 4011 1. To install, reverse the removal procedure. NOTE ^ Install new O-rings on fittings that are disconnected. Use only approved O-rings which contain a yellow identification stripe. ^ After installation is complete, perform the Fuel System Leak Test procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Specifications Fuel Temperature Sensor: Specifications Fuel Tank Temperature Sensor 40 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Upper) Sensor REMOVAL NOTE: The upper fuel tank temperature sensor is also referred to as fuel tank temperature sensor No.1. 1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box. 3. Remove the upper NGV fuel tank temperature sensor. 1 Disconnect the electrical connector. 2 Remove the fuel tank temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor > Page 4017 Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Lower) Sensor REMOVAL NOTE: The lower fuel tank temperature sensor is also referred to as fuel tank temperature sensor No.2. 1. Carry out the Pressure Relief Fuel Line Venting procedure. 2. Raise and support the vehicle. 3. Remove the lower NGV fuel tank shield upper nuts. 4. Remove the lower NGV fuel tank shield. 1 Remove the nuts. 2 Remove the lower NGV fuel tank shield. 5. Remove the lower NGV fuel tank temperature sensor. 1 Disconnect the lower NGV fuel tank temperature sensor electrical connector. 2 Remove the lower NGV fuel tank temperature sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor > Page 4018 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy ^ Replace the lower NGV fuel tank temperature sensor O-ring seal. ^ Lubricate the lower NGV fuel tank temperature sensor O-ring seal with Super Premium 5W30 engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to help seal and ease the installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control Valve: Specifications Idle Air Control Valve Bolts 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4022 Idle Air Control Valve: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine appearance cover. 3. Disconnect the electrical connector from the Idle Air Control (IAC) valve. 4. Remove the idle air control valve hose. 5. Remove the two screws and the idle air control valve. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4023 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement Technical Service Bulletin # 99B03 Date: 990301 Campaign - Inertia Switch Bracket Replacement 99B03 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch Original - March, 1999 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - May, 1999 1998-99 Crown Victoria/Grand Marquis - Inertia Switch IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4032 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4033 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 99B03 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hr. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4034 Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal processing channels. Inertia Bracket Kit: XW7Z-9D379-AA CLAIMS PREPARATION -- Entering using DWE -- Use code information shown below: ^ Program Code - 99B03 ^ Labor Operation - See above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE PROCEDURE 1. Open trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4035 2. Remove carpet pushpins from left inner quarter panel. See Figure 1. 3. Pull carpet away from left inner quarter panel. 4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner quarter panel reinforcement. Refer to Figure 2. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4036 5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an assembly. 6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT disconnect inertia switch electrical connector. 7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes. 8. Measure, mark and drill bottom anti-rotation hole as follows: ^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3. ^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at this location. ^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new location. ^ Using a 25/64 inch drill bit, drill hole at center punched location. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4037 9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4. 10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these locations. 11. Remove inertia switch bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4038 12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure 5. 13. Clean all metal shavings from luggage compartment. 14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft). 15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2 lb-ft). 16. Install wiring harness routing pushpins. 17. Press reset button on inertia switch. Make sure switch is set properly. 18. Reposition carpet back on left inner quarter panel. 19. Install carpet pushpins. 20. Close trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4039 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4040 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4041 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement Technical Service Bulletin # 99B03 Date: 990301 Campaign - Inertia Switch Bracket Replacement 99B03 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch Original - March, 1999 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - May, 1999 1998-99 Crown Victoria/Grand Marquis - Inertia Switch IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4047 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4048 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 99B03 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hr. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4049 Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal processing channels. Inertia Bracket Kit: XW7Z-9D379-AA CLAIMS PREPARATION -- Entering using DWE -- Use code information shown below: ^ Program Code - 99B03 ^ Labor Operation - See above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE PROCEDURE 1. Open trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4050 2. Remove carpet pushpins from left inner quarter panel. See Figure 1. 3. Pull carpet away from left inner quarter panel. 4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner quarter panel reinforcement. Refer to Figure 2. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4051 5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an assembly. 6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT disconnect inertia switch electrical connector. 7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes. 8. Measure, mark and drill bottom anti-rotation hole as follows: ^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3. ^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at this location. ^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new location. ^ Using a 25/64 inch drill bit, drill hole at center punched location. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4052 9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4. 10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these locations. 11. Remove inertia switch bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4053 12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure 5. 13. Clean all metal shavings from luggage compartment. 14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft). 15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2 lb-ft). 16. Install wiring harness routing pushpins. 17. Press reset button on inertia switch. Make sure switch is set properly. 18. Reposition carpet back on left inner quarter panel. 19. Install carpet pushpins. 20. Close trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4054 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4055 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4056 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Page 4057 Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Screws ............................................................................................................................................................ 1.0 Nm (9 in lbs) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Page 4058 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the luggage compartment door. 3. Disconnect the connector from the inertia fuel shutoff switch. 4. Remove the retaining screws from the inertia fuel shutoff switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 4064 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 4069 Fuel Injector Driver Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 4070 Fuel Injector Driver Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 4071 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 4072 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page 4076 Fuel Valve Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page 4077 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 4083 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4093 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4094 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4100 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4101 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 4102 Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Bolts 4-5 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 4103 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 4104 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Loosen the clamp and remove the air cleaner outlet tube. 4. Remove the four bolts and the mass air flow sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 4105 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Specifications Fuel Temperature Sensor: Specifications Fuel Tank Temperature Sensor 40 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Upper) Sensor REMOVAL NOTE: The upper fuel tank temperature sensor is also referred to as fuel tank temperature sensor No.1. 1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box. 3. Remove the upper NGV fuel tank temperature sensor. 1 Disconnect the electrical connector. 2 Remove the fuel tank temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor > Page 4111 Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Lower) Sensor REMOVAL NOTE: The lower fuel tank temperature sensor is also referred to as fuel tank temperature sensor No.2. 1. Carry out the Pressure Relief Fuel Line Venting procedure. 2. Raise and support the vehicle. 3. Remove the lower NGV fuel tank shield upper nuts. 4. Remove the lower NGV fuel tank shield. 1 Remove the nuts. 2 Remove the lower NGV fuel tank shield. 5. Remove the lower NGV fuel tank temperature sensor. 1 Disconnect the lower NGV fuel tank temperature sensor electrical connector. 2 Remove the lower NGV fuel tank temperature sensor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor > Page 4112 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy ^ Replace the lower NGV fuel tank temperature sensor O-ring seal. ^ Lubricate the lower NGV fuel tank temperature sensor O-ring seal with Super Premium 5W30 engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to help seal and ease the installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement Technical Service Bulletin # 99B03 Date: 990301 Campaign - Inertia Switch Bracket Replacement 99B03 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch Original - March, 1999 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - May, 1999 1998-99 Crown Victoria/Grand Marquis - Inertia Switch IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4121 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4122 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 99B03 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hr. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4123 Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal processing channels. Inertia Bracket Kit: XW7Z-9D379-AA CLAIMS PREPARATION -- Entering using DWE -- Use code information shown below: ^ Program Code - 99B03 ^ Labor Operation - See above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE PROCEDURE 1. Open trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4124 2. Remove carpet pushpins from left inner quarter panel. See Figure 1. 3. Pull carpet away from left inner quarter panel. 4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner quarter panel reinforcement. Refer to Figure 2. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4125 5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an assembly. 6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT disconnect inertia switch electrical connector. 7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes. 8. Measure, mark and drill bottom anti-rotation hole as follows: ^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3. ^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at this location. ^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new location. ^ Using a 25/64 inch drill bit, drill hole at center punched location. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4126 9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4. 10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these locations. 11. Remove inertia switch bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4127 12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure 5. 13. Clean all metal shavings from luggage compartment. 14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft). 15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2 lb-ft). 16. Install wiring harness routing pushpins. 17. Press reset button on inertia switch. Make sure switch is set properly. 18. Reposition carpet back on left inner quarter panel. 19. Install carpet pushpins. 20. Close trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4128 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4129 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4130 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement Technical Service Bulletin # 99B03 Date: 990301 Campaign - Inertia Switch Bracket Replacement 99B03 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch Original - March, 1999 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - May, 1999 1998-99 Crown Victoria/Grand Marquis - Inertia Switch IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4136 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4137 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 99B03 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hr. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4138 Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal processing channels. Inertia Bracket Kit: XW7Z-9D379-AA CLAIMS PREPARATION -- Entering using DWE -- Use code information shown below: ^ Program Code - 99B03 ^ Labor Operation - See above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE PROCEDURE 1. Open trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4139 2. Remove carpet pushpins from left inner quarter panel. See Figure 1. 3. Pull carpet away from left inner quarter panel. 4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner quarter panel reinforcement. Refer to Figure 2. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4140 5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an assembly. 6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT disconnect inertia switch electrical connector. 7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes. 8. Measure, mark and drill bottom anti-rotation hole as follows: ^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3. ^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at this location. ^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new location. ^ Using a 25/64 inch drill bit, drill hole at center punched location. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4141 9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4. 10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these locations. 11. Remove inertia switch bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4142 12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure 5. 13. Clean all metal shavings from luggage compartment. 14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft). 15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2 lb-ft). 16. Install wiring harness routing pushpins. 17. Press reset button on inertia switch. Make sure switch is set properly. 18. Reposition carpet back on left inner quarter panel. 19. Install carpet pushpins. 20. Close trunk. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4143 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4144 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4145 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Page 4146 Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Screws ............................................................................................................................................................ 1.0 Nm (9 in lbs) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Page 4147 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the luggage compartment door. 3. Disconnect the connector from the inertia fuel shutoff switch. 4. Remove the retaining screws from the inertia fuel shutoff switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine appearance cover. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the throttle position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body-to-Intake Manifold Spacer 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4154 Throttle Body: Description and Operation The throttle body: ^ controls air supply to the upper intake manifold by positioning the throttle plate. ^ connects the accelerator cable and, if equipped the speed control actuator cable to the throttle plate. ^ is not adjustable. ^ cannot be cleaned. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4155 Throttle Body: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: The throttle body bore and plate area have a special coating and cannot be cleaned. NOTE: Gasoline engine shown, natural gas similar. 1. Remove the air cleaner outlet tube. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Disconnect the accelerator cable and the speed control actuator cable. 4. Disconnect the throttle return spring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4156 5. Remove the four bolts and the throttle body NOTE: Discard the Throttle Body (TB) gasket. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Accelerator Cable Bracket Bolts 8-12 Nm Accelerator Cable Bracket to Intake Manifold Bolts 15-20 Nm Accelerator Cable Housing to Bracket Screw 8-12 Nm Accelerator Cable Housing to Dash Panel Nuts 3-4 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4160 Throttle Cable/Linkage: Description and Operation The throttle is controlled by the accelerator cable which is connected to the accelerator pedal and shaft. ^ The accelerator pedal and shaft should travel smoothly from the idle to the Wide-Open Throttle (WOT) positions. Hesitation on return and/or prevention of return to the idle position must not occur. ^ Surrounding components such as wiring, hoses, sound insulator and floor covering must not contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft. ^ The sliding inner member accelerator cable should not be lubricated and is not serviceable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4161 Throttle Cable/Linkage: Service and Repair REMOVAL 1. Remove the front engine appearance cover and the throttle return spring. 2. Disconnect the accelerator cable from the throttle body lever. 3. Remove the screw (cable to bracket) and remove the accelerator cable from the accelerator cable bracket. 4. Remove the accelerator cable from the clip. 5. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4162 6. Disconnect the accelerator cable from the accelerator pedal and shaft. 7. Remove the accelerator cable retainer. 8. Pull the cable through the dash panel and remove from the vehicles. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine appearance cover. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the throttle position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order 1-3-7-2-6-5-4-8 Coil On Plug Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4177 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4181 Crankshaft Position Sensor: Description and Operation The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4182 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the two bolts and position the A/C compressor out of the way. 6. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4183 7. Remove the crankshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips Ignition Coil: Technical Service Bulletins Ignition System - Coil-On-Plug Misfire Diagnostic Tips TSB 05-22-8 11/14/05 WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING FORD: 1996-1999 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-2005 Thunderbird 2003-2006 Focus 2004-2006 Taurus 2005-2006 Five Hundred, Freestyle 1997-2006 E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-2005 Excursion, F-53 2001-2006 Escape 2002-2005 Explorer 2005-2006 Escape Hybrid LINCOLN: 1997-1998 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-2006 LS 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1998-2006 Grand Marquis 2000 Sable 2004-2005 Sable 2005-2006 Montego 2002-2005 Mountaineer 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 04-16-01 to update the vehicle applications and model years. NOTE FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs RELEASED FOR THE VEHICLE SYMPTOM BEING EXPERIENCED. ISSUE Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem. ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition problems (be sure to rule out coil primary circuit issues). Once the above steps have been completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure outlined in this TSB can isolate the difference between a coil or spark plug problem. SERVICE PROCEDURE The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through 1-800-ROTUNDA. The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire diagnosis using the COP Kit. The following procedure is for cylinder specific misfires and not random misfires. Random misfires have a different root cause and are not covered by this TSB. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4188 Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes for a cylinder specific misfire could be fuel, spark, or mechanical problems. Perform a thorough visual inspection. If no visible concerns are found use the following WDS tools for misfire diagnosis: ^ Self-test (Check for codes first) Power Balance (Identify the cylinder of concern) ^ Relative Compression (Rule out a possible mechanical issue) ^ Fuel (Make sure fuel injectors are not restricted) ^ Ignition (Make sure spark plugs and coils are working properly) ^ Oscilloscope (Detailed signal analysis) NOTE USE THE ENCYCLOPEDIA BUTTON IN THE LOWER LEFT CORNER OF THE SCREEN FOR DETAILED INFORMATION ON THE WDS TOOL BEING DISPLAYED. If there is a self-test code identifying a particular cylinder then you just need to determine if it is a fuel, ignition, or possibly a mechanical problem. Proceed to Step 2 after running Relative Compression to rule out any mechanical issues. If there is no self-test code and the customer concern is a miss, proceed to Step 1. Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4189 The cylinder specific miss has to be identified as shown in the example in Figure 2 in order to proceed with the remaining steps. If the miss does not occur at idle (in the bay), try to brake torque the engine. This extra loading should reproduce the miss in the bay. If the miss cannot be reproduced during brake torque, select Relative Compression under Powertrain on WDS before going on a road test to rule out mechanical problems. If Relative Compression shows a problem then the base engine issue must be serviced. If Relative Compression results are good (Figure 3), road test under as many different driving conditions as possible until the miss occurs on Power Balance. Some misses may be very intermiffent so be patient and concentrate on steady load conditions. Once a cylinder dropout is identified proceed to Step 2. Step 2: (Select Toolbox Icon, then Powertrain, then Fuel System Test) Run Fuel System Test on WDS to determine if there may be a fuel problem. After completing fuel Pressure/Leakdown test, select Injector flow to isolate Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4190 a restricted injector as shown in Figure 4. If all the injectors are within specification, proceed to Step 3. Step 3: (Select Toolbox Icon, then Powertrain, then Ignition System Test) Run Ignition System Test on WDS to determine if there is an ignition problem. Look at both duration (DUR) and kilovolts (KV) and look for values that standout from the rest as shown in Figure 5 and Figure 6. NOTE LIVE DISPLAY HAS TO AVERAGE IGNITION VALUES BECAUSE THERE IS TOO MUCH DATA TO DISPLAY. MAKE A CAPTURE TO VIEW EACH ENGINE EVENT WITHOUT AVERAGING. THIS CAN BE HELPFUL WHEN THE PROBLEM IS INTERMITTENT. IF THE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4191 MISS IS EXTREMELY INTERMITTENT AND DOES NOT SHOW UP IN IGNITION, PROCEED TO STEP 4. If either spark duration or peak KV on the Red Probe (Suspect Cylinder) are offset from the values displayed on the Black Probe (Known Good Cylinder) then the problem is in the ignition system. Rule out coil primary circuit issues before proceeding to coil secondary issues such as the spark plug , coil boot, or possibly the coil. Use the WDS Oscilloscope with the COP kit to determine if the issue is the coil or the spark plug. Step 4: (Select Toolbox, then Oscilloscope) WARNING SECONDARY IGNITION VOLTAGES ARE VERY HIGH. KEEP HANDS AND TOOLS AWAY FROM THE END OF THE COIL THAT SUPPLIES THE SPARK. SET-UP: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so the coil cannot spark to any other surface as shown in Figure 1. Wrap a clean shop cloth around the hard shell of the coil to help keep the coil propped up and stable. CAUTION THE COIL BOOT CAN BE DAMAGED IF THE COIL SPARKS TO ANOTHER SURFACE DURING THIS PROCEDURE. Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route the coil clip wire and cable away from the coil being tested as well as other coils to avoid noise interference. Disconnect the injector of the cylinder being tested so raw fuel is not washing the cylinder. This is a stress test for the coil. The type of waveform displayed on the oscilloscope will show whether a coil or the plug is the problem if all previous steps have been followed. Keep hands and tools away from the end of the coil that supplies the spark. COP Stress Test Procedure: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4192 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4193 Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select COP_STRESS_TEST_RED. This pre-configured setting will zoom-in on the peak firing of the coil being tested. Start the engine and be sure the coil is not sparking to any surface. If the coil is sparking to other surfaces, turn the engine off immediately and readjust the coil so it cannot spark to any other surface. Restart the engine and touch the Red Man icon to start the oscilloscope. All settings are pre-configured and no adjustments are necessary. Compare the waveform you get with the examples provided in Figures 7, 8, and 9). Figure 7 is a good waveform. If your waveform is similar to Figure 7 the coil is working correctly. Suspect the spark plug. Figure 8 and Figure 9 are examples of problem coils. Replace the coil if the waveform is similar to Figures 8 or 9. The coil is causing the misfire when the peak firing appears like those shown in Figures 8 and 9. Notice the difference in the peak-firing signal when compared to the good peak signal in Figure 7. Figure 9 shows a more dramatic fault in the peak failure. Most root causes of misfire issues can be identified quickly using the steps outlined above. Some misfire issues can be difficult making the oscilloscope an important part of your diagnostic toolbox. OTHER APPLICABLE ARTICLES: 05-13-4 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4194 Ignition Coil: Diagrams Firing Order 1-3-7-2-6-5-4-8 Coil On Plug Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4198 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Nut 20-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 4202 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower intake manifold. 3. Disconnect the electrical connector from the Knock Sensor (KS). 4. Remove the nut and the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4207 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4212 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4216 Crankshaft Position Sensor: Description and Operation The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4217 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the two bolts and position the A/C compressor out of the way. 6. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4218 7. Remove the crankshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4224 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4225 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4226 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4227 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4228 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4229 Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4232 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Service Precautions WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4233 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the steering column lock housing bearing and steering column lock gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing bearing. ^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three o'clock position. Rotate it counterclockwise. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4234 2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install the steering wheel. 4. Install the ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Nut 20-30 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 4238 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower intake manifold. 3. Disconnect the electrical connector from the Knock Sensor (KS). 4. Remove the nut and the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plugs 20 Nm Spark Plug Gap 1.32-1.42 mm Spark Plug Type AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 4243 Spark Plug: Specifications Spark Plugs 20 Nm Spark Plug Gap 1.32-1.42 mm Spark Plug Type AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4244 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................................................... AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4245 Spark Plug: Description and Operation The spark plugs: ^ change a high voltage pulse into a spark which ignites the fuel and air mixture. ^ originally equipped on the vehicle have a platinum-enhanced active electrode for long life. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4246 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil. 2. Remove the spark plugs. NOTE: Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 3. Inspect the spark plugs for a gap bridged. ^ Check for deposit build-up closing the gap between electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 4. Inspect 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4247 5. Inspect for carbon fouling, identified by black, dry, fluffy carbon deposits on insulator tips, exposed shell surfaces and electrodes. This is caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 6. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 7. Inspect for pre-ignition, ^ identified by melted electrodes and possibly a damaged insulator. Metallic deposits on the insulator indicate engine damage, which may be caused by incorrect ignition timing, wrong type of fuel or the installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 8. Inspect for overheating, identified by a white or light gray insulator with small black or gray-brown spots with bluish-burnt appearance of electrodes. This can be caused by engine overheating, the wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4248 ^ Install a new spark plug. 9. Inspect for fused spot deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. 10. Adjust the spark plug gap as required. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair Electronic Pressure Control Solenoid: Service and Repair Removal 1. Remove the manual control lever. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 2. Disconnect the molded lead frame from the solenoids. 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC). 3. Disconnect the Electronic Pressure Control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation 1. Install the Electronic Pressure Control (EPC) solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair > Page 4255 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Retaining Screw .................................................................................................................................. .................................................... 9 Nm (80 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 4259 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. 3. Remove the insert plate from the shift lock actuator. ^ Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the automatic transmission. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission range selector lever in the OD position. ^ Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (OD position). 3. Hang a 1.36 Kg (3 lbs.) weight on the range selector lever. 4. Center the pointer in the middle of the OD position. ^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 1.36 Kg (3 lbs.) weight. 6. Carefully move the shift range selector lever from detent to detent and compare with transmission settings. ^ Re-adjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock Inoperative > Page 4281 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4287 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4291 Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4292 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4296 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4297 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Loosen the digital Transmission Range (TR) bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4298 7. Tighten the bolts. 8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR sensor electrical connector. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4299 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4303 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed Technical Service Bulletin # 99B04 Date: 990301 Campaign - PCM Reflashing, Reduced Top Speed 99B04 OWNER NOTIFICATION PROGRAM Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4312 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4313 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4314 For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information No parts are required for this program. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 99B04 ^ Labor Operation: B04B See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998 SERVICE PROCEDURE 1. Check the PCM calibration as follows: ^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information. ^ Cross reference data to information below to determine the calibration level. 2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD (current R level) using one of the following two (2) methods: ^ Service Bay Diagnostic System (SBDS). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4315 ^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with Rotunda flash cable (007-00531) and Rotunda flash card (007-00532). 3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P & A Code, date of repair and the recall program type and program number as shown below. 4. Apply label to clear area of the upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4316 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4317 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4323 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4324 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 00-8-1 > Apr > 00 > PCM - Rough Idle On Cold Engine Start Up PROM - Programmable Read Only Memory: Customer Interest PCM - Rough Idle On Cold Engine Start Up Article No. 00-8-1 DATE: 04/17/2000 IDLE - ROUGH - AFTER COLD ENGINE START-UP (12 HOUR SOAK) - VEHICLES BUILT THROUGH 7/15/1998 FORD: 1998-1999 CROWN VICTORIA ISSUE A rough idle approximately 20 seconds after a cold engine start-up may occur on some vehicles. This condition will usually occur after a 12 hour soak, with ambient temperatures above 10° C (50 ° F). This may be due to a Powertrain Control Module (PCM) calibration ACTION Perform normal diagnostics in accordance with the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, then reprogram the PCM with the latest level calibration using World Diagnostic System (WDS) or New Generation Star (NGS) Tester Refer to the following PCM Reprogramming Information Chart to identify the appropriate calibration. Recalibration Information OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible under the provisions of bumper to bumper warranty coverage and emmission warranty coverage. OPERATION DESCRIPTION TIME 000801A reprogram powertrain 0.4 HR control module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 608000, 608400, 609000, 609400. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing PROM - Programmable Read Only Memory: Customer Interest A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4333 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4334 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation Above 90 Degrees F. PROM - Programmable Read Only Memory: Customer Interest Engine - Spark Knock/Detonation Above 90 Degrees F. Article No. 99-15-5 07/26/99 SPARK KNOCK - DURING ACCELERATION IN AMBIENT TEMPERATURES GREATER THAN 32 DEGREES C (90 DEGREES F) - VEHICLES BUILT THROUGH 1/1999 FORD: 1999 CROWN VICTORIA MERCURY: 1999 GRAND MARQUIS ISSUE A light spark knock/detonation may occur while accelerating in ambient temperatures greater than 32°C (90°F). This may be caused by the Powertrain Control Module (PCM) calibration. ACTION Reprogram the PCM. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics in accordance with the 1999 Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual and repair as necessary. 2. If no problem was found, reprogram the PCM with the latest level calibration using Service Bay Diagnostic System (SBDS) or New Generation Star (NGS) Tester. Refer to the following PCM Reprogramming Information Chart to identify the appropriate calibration. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: 98-25-18 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation Above 90 Degrees F. > Page 4339 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991505A Reprogram Powertrain 0.6 Hr. Control Module (PCM) 991505B If PC/ED Diagnostics Are Required, Use "A" Time Per The Warranty And Policy Manual DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4345 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4346 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4351 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4352 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 00-8-1 > Apr > 00 > PCM - Rough Idle On Cold Engine Start Up PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Rough Idle On Cold Engine Start Up Article No. 00-8-1 DATE: 04/17/2000 IDLE - ROUGH - AFTER COLD ENGINE START-UP (12 HOUR SOAK) - VEHICLES BUILT THROUGH 7/15/1998 FORD: 1998-1999 CROWN VICTORIA ISSUE A rough idle approximately 20 seconds after a cold engine start-up may occur on some vehicles. This condition will usually occur after a 12 hour soak, with ambient temperatures above 10° C (50 ° F). This may be due to a Powertrain Control Module (PCM) calibration ACTION Perform normal diagnostics in accordance with the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, then reprogram the PCM with the latest level calibration using World Diagnostic System (WDS) or New Generation Star (NGS) Tester Refer to the following PCM Reprogramming Information Chart to identify the appropriate calibration. Recalibration Information OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible under the provisions of bumper to bumper warranty coverage and emmission warranty coverage. OPERATION DESCRIPTION TIME 000801A reprogram powertrain 0.4 HR control module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 608000, 608400, 609000, 609400. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4361 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4362 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation Above 90 Degrees F. PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark Knock/Detonation Above 90 Degrees F. Article No. 99-15-5 07/26/99 SPARK KNOCK - DURING ACCELERATION IN AMBIENT TEMPERATURES GREATER THAN 32 DEGREES C (90 DEGREES F) - VEHICLES BUILT THROUGH 1/1999 FORD: 1999 CROWN VICTORIA MERCURY: 1999 GRAND MARQUIS ISSUE A light spark knock/detonation may occur while accelerating in ambient temperatures greater than 32°C (90°F). This may be caused by the Powertrain Control Module (PCM) calibration. ACTION Reprogram the PCM. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics in accordance with the 1999 Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual and repair as necessary. 2. If no problem was found, reprogram the PCM with the latest level calibration using Service Bay Diagnostic System (SBDS) or New Generation Star (NGS) Tester. Refer to the following PCM Reprogramming Information Chart to identify the appropriate calibration. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: 98-25-18 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation Above 90 Degrees F. > Page 4367 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991505A Reprogram Powertrain 0.6 Hr. Control Module (PCM) 991505B If PC/ED Diagnostics Are Required, Use "A" Time Per The Warranty And Policy Manual DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed Technical Service Bulletin # 99B04 Date: 990301 Campaign - PCM Reflashing, Reduced Top Speed 99B04 OWNER NOTIFICATION PROGRAM Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4372 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4373 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4374 For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information No parts are required for this program. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 99B04 ^ Labor Operation: B04B See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998 SERVICE PROCEDURE 1. Check the PCM calibration as follows: ^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information. ^ Cross reference data to information below to determine the calibration level. 2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD (current R level) using one of the following two (2) methods: ^ Service Bay Diagnostic System (SBDS). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4375 ^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with Rotunda flash cable (007-00531) and Rotunda flash card (007-00532). 3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P & A Code, date of repair and the recall program type and program number as shown below. 4. Apply label to clear area of the upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4376 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4377 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4383 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4384 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating Technical Service Bulletin # 00-10-3 Date: 000515 PCM - Engine Spark Knock While Accelerating Article No. 00-10-3 05/15/00 SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F) FORD: 1998-1999 CROWN VICTORIA MERCURY: 1998-1999 GRAND MARQUIS ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark advance commanded by the calibration when operating in high ambient temperatures. ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following Service Procedure for details. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 001003A Reprogram Powertrain 1.3 Hrs. Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans (Also Includes Time To Test Drive To Check For Spark knock) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4389 Service Procedure 1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2. 2. Verify high and low speed cooling fan operation using NGS and the following Steps. 3. Select DIAGNOSTIC DATA LINK. 4. Select PCM. 5. Select active command modes. 6. Select output test mode. 7. Select mode low fan. 8. Push START and verify low speed cooling fan operation. Push STOP. 9. Select mode high fan. 10. Push START and verify high speed fan operation. Push STOP. 11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Step. 12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB. 13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14. NOTE: USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY ONCE, AND IS NOT REVERSIBLE. 14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sure that you adjust the timing and not the octane rating as follows in the following Steps. 15. Make sure the battery is fully charged. 16. Turn ignition key on. 17. Install the latest calibration card. 18. Select PCM programming. 19. Enter 8 numbers (anything, 22222222). 20. The window will show the calibration #. 21. Select TRIGGER.. 22. Hook up the NGS cable. 23. Cycle the ignition key off, then on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4390 24. Select TRIGGER. 25. Turn the ignition key on. 26. Select YES. 27. The window will display the latest calibration. 28. Select YES to modify the PCM parameters. 29. Select OCTANE ADJUST. 30. Select RETARD using the thumbwheel. 31. Select START to activate octane adjust. 32. The window should display PCM update successfully completed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 00-8-1 > Apr > 00 > PCM - Rough Idle On Cold Engine Start Up PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Rough Idle On Cold Engine Start Up Article No. 00-8-1 DATE: 04/17/2000 IDLE - ROUGH - AFTER COLD ENGINE START-UP (12 HOUR SOAK) - VEHICLES BUILT THROUGH 7/15/1998 FORD: 1998-1999 CROWN VICTORIA ISSUE A rough idle approximately 20 seconds after a cold engine start-up may occur on some vehicles. This condition will usually occur after a 12 hour soak, with ambient temperatures above 10° C (50 ° F). This may be due to a Powertrain Control Module (PCM) calibration ACTION Perform normal diagnostics in accordance with the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, then reprogram the PCM with the latest level calibration using World Diagnostic System (WDS) or New Generation Star (NGS) Tester Refer to the following PCM Reprogramming Information Chart to identify the appropriate calibration. Recalibration Information OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible under the provisions of bumper to bumper warranty coverage and emmission warranty coverage. OPERATION DESCRIPTION TIME 000801A reprogram powertrain 0.4 HR control module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 608000, 608400, 609000, 609400. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4399 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4400 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation Above 90 Degrees F. PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark Knock/Detonation Above 90 Degrees F. Article No. 99-15-5 07/26/99 SPARK KNOCK - DURING ACCELERATION IN AMBIENT TEMPERATURES GREATER THAN 32 DEGREES C (90 DEGREES F) - VEHICLES BUILT THROUGH 1/1999 FORD: 1999 CROWN VICTORIA MERCURY: 1999 GRAND MARQUIS ISSUE A light spark knock/detonation may occur while accelerating in ambient temperatures greater than 32°C (90°F). This may be caused by the Powertrain Control Module (PCM) calibration. ACTION Reprogram the PCM. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics in accordance with the 1999 Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual and repair as necessary. 2. If no problem was found, reprogram the PCM with the latest level calibration using Service Bay Diagnostic System (SBDS) or New Generation Star (NGS) Tester. Refer to the following PCM Reprogramming Information Chart to identify the appropriate calibration. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: 98-25-18 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation Above 90 Degrees F. > Page 4405 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991505A Reprogram Powertrain 0.6 Hr. Control Module (PCM) 991505B If PC/ED Diagnostics Are Required, Use "A" Time Per The Warranty And Policy Manual DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4411 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4412 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed Technical Service Bulletin # 99B04 Date: 990301 Campaign - PCM Reflashing, Reduced Top Speed 99B04 OWNER NOTIFICATION PROGRAM Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4417 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4418 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4419 For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information No parts are required for this program. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 99B04 ^ Labor Operation: B04B See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998 SERVICE PROCEDURE 1. Check the PCM calibration as follows: ^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information. ^ Cross reference data to information below to determine the calibration level. 2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD (current R level) using one of the following two (2) methods: ^ Service Bay Diagnostic System (SBDS). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4420 ^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with Rotunda flash cable (007-00531) and Rotunda flash card (007-00532). 3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P & A Code, date of repair and the recall program type and program number as shown below. 4. Apply label to clear area of the upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4421 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4422 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair Electronic Pressure Control Solenoid: Service and Repair Removal 1. Remove the manual control lever. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 2. Disconnect the molded lead frame from the solenoids. 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC). 3. Disconnect the Electronic Pressure Control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation 1. Install the Electronic Pressure Control (EPC) solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair > Page 4429 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Retaining Screw .................................................................................................................................. .................................................... 9 Nm (80 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 4433 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. 3. Remove the insert plate from the shift lock actuator. ^ Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair Electronic Pressure Control Solenoid: Service and Repair Removal 1. Remove the manual control lever. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 2. Disconnect the molded lead frame from the solenoids. 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC). 3. Disconnect the Electronic Pressure Control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation 1. Install the Electronic Pressure Control (EPC) solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair > Page 4442 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Retaining Screw .................................................................................................................................. .................................................... 9 Nm (80 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 4446 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. 3. Remove the insert plate from the shift lock actuator. ^ Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4458 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: All Technical Service Bulletins A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4464 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator Accumulator: Service and Repair 1-2 Accumulator Special Tools Removal 1. Use (A) Servo Piston Remover Replacer to compress the 1-2 accumulator cover and remove the (B) accumulator piston retaining ring. NOTE: Note the location of the 1-2 accumulator springs for reference during assembly. 2. 1. Remove the 1-2 accumulator cover. 2. Remove the lower 1-2 accumulator spring. 3. Remove the accumulator piston. 4. Remove the upper 1-2 accumulator spring. Installation 1. Install the 1-2 accumulator. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 4467 1. Install the 1-2 accumulator upper spring. 2. Install the accumulator piston. 3. Install the 1-2 accumulator lower spring. 4. Install the cover and seal assembly. 2. Use (A) Servo Piston Remover Replacer to install the (B) accumulator piston retaining ring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 4468 Accumulator: Service and Repair 2-3 Accumulator Removal 1. Remove the main control valve body. 2. Remove the 2-3 accumulator piston retainer. 3. Remove the accumulator piston and spring. Installation 1. Install the 2-3 accumulator assembly. 1. Install the accumulator piston. 2. Install the accumulator piston spring. 3. Install the accumulator spring retainer. 2. Install the main control valve body. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 4469 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo Band Apply Servo: Service and Repair Overdrive Servo Special Tools Removal 1. Remove the main control valve body. NOTE: If the tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on overdrive servo internal retaining ring. 2. Use (A) Servo Piston Remover/Replacer to compress the servo spring then remove the (B) overdrive servo retaining ring. 3. Remove the (A) overdrive servo piston and the (B) overdrive servo piston return spring. Installation 1. Install the overdrive servo piston assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 4477 1. Install the overdrive servo piston return spring. 2. Install the overdrive servo piston assembly. 2. Use (A) Servo Piston Remover/Replacer Tool to install the (B) overdrive servo piston retaining ring. 3. Install the main control valve body. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 4478 Band Apply Servo: Service and Repair Reverse Servo Assembly Special Tools Removal 1. Remove the main control valve body. 2. Use the Servo Piston Remover/Replacer to remove the reverse band servo retaining ring. 1. Compress the servo spring. 2. Remove the reverse band servo retaining ring. NOTE: The length of the rod attached to the piston is graded for three different lengths. Therefore, they should not be installed in any transmission other than the transmission from which they were removed. 3. Remove the (A) reverse band servo cover , (B) reverse band servo piston and rod and (C) reverse band servo spring. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 4479 NOTE: ^ This is not an ordinary installation procedure and does not compensate for band wear. ^ Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal. 1. Install the reverse servo piston and return spring. ^ Do not install the piston cover. 2. Install the Servo Piston Selection Tool and tighten the band apply bolt. 3. Attach the Dial Indicator With Bracketry. ^ Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator. 4. Loosen the bolt until the piston stops against the tool. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 4480 5. Verify the amount of piston travel on the dial indicator is within specification. 6. If piston travel is not within specification, select the proper servo assembly (A) one groove, (B) two groove or (C) three groove, to bring the servo piston travel within specification. 7. Remove the dial indicator and servo selection tool. 8. Install the proper servo piston assembly spring and the reverse servo piston cover and seal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 4481 9. Use the Servo Piston Remover/Replacer to install the reverse servo retaining ring. 1. Compress the servo spring. 2. Install the reverse band servo retaining ring. 10. Install the main control valve body. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 4482 Band Apply Servo: Tools and Equipment Special Tools Special Tools Special Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T > Page 4487 Clutch: Specifications Clearance 0.062 - 0.85 in Snap Ring Thickness 0.050 - 0.054 0.064 - 0.068 0.078 - 0.082 0.092 - 0.096 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T > Page 4488 Clutch: Specifications Clearance 0.050 - 0.094 in Snap Ring Thickness 0.060 - 0.064 in. 0.074 - 0.078 in. 0.088 - 0.092 in. 0.102 - 0.106 in. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T > Page 4489 Clutch: Specifications Clearance 1.643 - 1.677 in Snap Ring Thickness 0.067 - 0.071 in 0.077 - 0.081 in 0.087 - 0.091 in 0.097 - 0.101 in Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T > Page 4490 Clutch: Specifications Clearance 0.040 - 0.060 in Snap Ring Thickness 0.060 - 0.064 in 0.074 - 0.078 in 0.088 - 0.092 in 0.102 - 0.106 in Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair Automatic Transmission Dipstick - Dipstick Tube: Service and Repair Removal 1. Remove the bolt. 2. Remove the fluid filler tube. Installation 1. Follow removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed Technical Service Bulletin # 99B04 Date: 990301 Campaign - PCM Reflashing, Reduced Top Speed 99B04 OWNER NOTIFICATION PROGRAM Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4502 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4503 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4504 For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information No parts are required for this program. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 99B04 ^ Labor Operation: B04B See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998 SERVICE PROCEDURE 1. Check the PCM calibration as follows: ^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information. ^ Cross reference data to information below to determine the calibration level. 2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD (current R level) using one of the following two (2) methods: ^ Service Bay Diagnostic System (SBDS). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4505 ^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with Rotunda flash cable (007-00531) and Rotunda flash card (007-00532). 3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P & A Code, date of repair and the recall program type and program number as shown below. 4. Apply label to clear area of the upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4506 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4507 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing Extension Housing: Customer Interest A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4513 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4514 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing Extension Housing: All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4520 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4521 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed Technical Service Bulletin # 99B04 Date: 990301 Campaign - PCM Reflashing, Reduced Top Speed 99B04 OWNER NOTIFICATION PROGRAM Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4526 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4527 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4528 For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information No parts are required for this program. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 99B04 ^ Labor Operation: B04B See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998 SERVICE PROCEDURE 1. Check the PCM calibration as follows: ^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information. ^ Cross reference data to information below to determine the calibration level. 2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD (current R level) using one of the following two (2) methods: ^ Service Bay Diagnostic System (SBDS). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4529 ^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with Rotunda flash cable (007-00531) and Rotunda flash card (007-00532). 3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P & A Code, date of repair and the recall program type and program number as shown below. 4. Apply label to clear area of the upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4530 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4531 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing Extension Housing: All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4537 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4538 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed Technical Service Bulletin # 99B04 Date: 990301 Campaign - PCM Reflashing, Reduced Top Speed 99B04 OWNER NOTIFICATION PROGRAM Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4544 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4545 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4546 For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information No parts are required for this program. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 99B04 ^ Labor Operation: B04B See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998 SERVICE PROCEDURE 1. Check the PCM calibration as follows: ^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information. ^ Cross reference data to information below to determine the calibration level. 2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD (current R level) using one of the following two (2) methods: ^ Service Bay Diagnostic System (SBDS). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4547 ^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with Rotunda flash cable (007-00531) and Rotunda flash card (007-00532). 3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P & A Code, date of repair and the recall program type and program number as shown below. 4. Apply label to clear area of the upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4548 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4549 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Page 4550 Extension Housing: Specifications Extension Housing Bolts 19 - 22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid .............................................................................................................................................. ........................................................ 13.1L (13.8 Qt) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4555 Fluid - A/T: Fluid Type Specifications Item ...................................................................................................................................................... ............................................................. Specification Motorcraft MERCON V Automatic Transmission Fluid ................................................................................................................................... MERCON V Note: MERCON V is not interchangeable at this time with the current MERCON service fluids. Check the transmission dipstick to determine the correct fluid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4556 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4557 Fluid - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, etc., is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter, transmission cooler tubes must be thoroughly flushed to remove any dirt and the oil-to-air cooler must be replaced. The oil-to-air cooler must be replaced under the following conditions: 1. Evidence of transmission assembly or fluid contamination is found due to the following transmission or converter failure modes: ^ major metallic failure ^ multiple clutches or clutch plate failures 2. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid. ^ Normal Maintenance Change fluid at 48,279 km (30,000 miles). ^ Severe Duty/Major Overhaul Change fluid at 33,795 km (21,000 miles). CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. 2. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specifications for capacity. Check the fluid level. Removal 1. If equipped deactivate the air suspension. 2. Disconnect the battery ground cable 3. Raise the vehicle on a hoist. 4. Place a drain pan under the transmission fluid pan. 5. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. ^ Replace transmission fluid pan gasket as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4558 7. Remove torque converter housing plug. 8. Remove the torque converter drain plug and drain the torque converter. ^ Rotate the crankshaft to access the drain plug. 9. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 10. Flush the fluid cooler tubes. 11. Flush the torque converter. Installation NOTE: A new torque converter drain plug must be used. 1. Install the torque converter drain plug. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4559 2. Install the torque converter housing plug. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. 3. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. 5. Install the transmission fluid pan and gasket. 1. Position transmission fluid pan gasket. 2. Position the transmission fluid pan. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4560 6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped reactivate the air suspension.. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). 10. Fill transmission to proper fluid level. ^ Use Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent fluid meeting Ford specification MERCON V(R). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Cooler Tube Nut to Case Fitting 13 ft.lb Fluid Cooler Line Case Fittings 15 - 19 ft.lb Fluid Cooler Tube Nut 13 - 16 ft.lb Cooler Line Clip-to-Engine Bolt 30 - 40 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4564 Fluid Line/Hose: Service and Repair Removal 1. Remove the radiator cover. 2. Remove the battery. 3. Remove the air filter assembly. 4. Remove the fluid cooler tube and the fluid cooler outlet tube from the fluid cooler. 5. Remove the hose routing bracket at the frame. 6. Remove the line routing bracket at the engine. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4565 7. Remove the transmission cooler lines. ^ Remove the fluid cooler inlet tube. ^ Remove the fluid cooler tube. Installation 1. Install the transmission cooler lines. ^ Install the fluid cooler tube. ^ Install the fluid cooler inlet tube. 2. Install the line routing bracket and bolt at the engine. 3. Install the hose routing bracket and bolt at the frame. 4. Connect the fluid cooler inlet tube and the fluid cooler outlet tube. 5. Install the air filter assembly. 6. Install the battery. 7. Fill the transmission fluid to the proper level using Motorcraft MERCON @ V Automatic Transmission fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Inspect for leaks. 8. Install the radiator cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4566 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Transmission Fluid Pan Bolts 9 - 11 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4570 Fluid Pan: Service and Repair Removal 1. Deactivate the air suspension 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Place a drain pan under the transmission fluid pan. 5. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. 7. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 8. Remove torque converter housing plug. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4571 9. Remove the torque converter drain plug and drain the torque converter. Rotate the crankshaft to access the drain plug. 10. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 11. Flush the fluid cooler tubes. 12. Flush the torque converter. Installation NOTE: A new torque converter drain plug must be used. 1. Install the torque converter drain plug. 2. Install torque converter housing plug. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4572 NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. 3. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. 5. Install the transmission fluid pan and gasket. 1. Position transmission fluid pan gasket. 2. Position the transmission fluid pan. 6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4573 NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). 10. Fill transmission to proper fluid level. ^ Use Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON(R) V. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Front Pump Bolts 15 - 19 ft.lb Front Pump Support Bolts 15 - 19 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the automatic transmission. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission range selector lever in the OD position. ^ Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (OD position). 3. Hang a 1.36 Kg (3 lbs.) weight on the range selector lever. 4. Center the pointer in the middle of the OD position. ^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 1.36 Kg (3 lbs.) weight. 6. Carefully move the shift range selector lever from detent to detent and compare with transmission settings. ^ Re-adjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the automatic transmission. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: Customer Interest A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4595 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4596 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4597 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: All Technical Service Bulletins A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4603 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4604 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4605 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair Electronic Pressure Control Solenoid: Service and Repair Removal 1. Remove the manual control lever. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 2. Disconnect the molded lead frame from the solenoids. 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC). 3. Disconnect the Electronic Pressure Control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation 1. Install the Electronic Pressure Control (EPC) solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair > Page 4609 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair Special Tools Removal 1. Turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Drain the transmission fluid. NOTE: To maintain the initial driveshaft balance, mark the rear driveshaft yoke and the axle flange so they may be installed in their original positions. 5. Remove the driveshaft. ^ Remove the four bolts. 6. Separate the driveshaft from the transmission. 7. Use a High-Lift Transmission Jack to support the transmission. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 4613 8. Remove the two transmission mount nuts. 9. Remove the transmission crossmember. ^ Remove the bolts. ^ Remove the transmission crossmember. 10. Lower the transmission to access the extension housing bolts. 11. Use the (A) Seal Remover and the (B) Impact Slide Hammer to remove the (c) extension housing seal. 12. Remove the extension housing and gasket. 1. Remove the bolts and the nuts. 2. Remove the extension housing and gasket. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 4614 1. Install the extension housing and gasket. 1. Position the extension housing gasket and the extension housing. 2. Install the bolts and the nuts. 2. Install the new extension housing seal. 1. Align Extension Housing Seal Replacer with the seal. 2. Install the extension housing seal. 3. Raise and position the transmission. 4. Install the transmission crossmember. 1. Position the transmission crossmember. 2. Install the bolts. 5. Remove High-Lift Transmission Jack. 6. Install the two transmission mount nuts. NOTE: The output shaft and the drive shaft are a balanced assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 4615 7. Install the driveshaft. ^ Align the yellow dots and position the driveshaft on the transmission. ^ Position the driveshaft to the rear differential. 8. Install the four retaining bolts. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. If equipped reactivate the air suspension. 12. Fill the transmission with fluid and inspect for proper operation. ^ Use Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON(R) V. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 4616 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4626 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4632 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4636 Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4637 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4641 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4642 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Loosen the digital Transmission Range (TR) bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4643 7. Tighten the bolts. 8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR sensor electrical connector. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4644 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4648 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Retaining Screw .................................................................................................................................. .................................................... 9 Nm (80 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 4653 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. 3. Remove the insert plate from the shift lock actuator. ^ Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4662 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4668 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications Transmission Select Lever .................................................................................................................. ...................................................... 15 Nm (11 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Page 4672 Shifter A/T: Service and Repair Removal 1. Remove the ignition switch lock cylinder. 2. Remove the upper steering column shroud. 3. Remove the transmission range selector lever. 1. Disconnect the electrical connector. 2. Remove and discard the selector lever pin. 3. Remove the selector lever. Installation NOTE: The selector lever pin must be replaced whenever removed. 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications Selector Shaft: Specifications Manual Lever Shaft Nut 20 - 27 ft.lb Manual Lever Shaft Outer Nut 23 - 25 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4677 Selector Shaft: Service and Repair Special Tools Removal 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. . 4. Drain the transmission fluid and remove the fluid pan and filter. 5. Disconnect the digital Transmission Range (TR) sensor electrical connector. 6. Disconnect the transmission shift linkage. 7. Remove the digital TR sensor. ^ Remove the bolts. ^ Remove the digital TR sensor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4678 8. Remove the manual control valve detent lever spring. 1. Remove the bolt. 2. Remove the manual control valve detent lever spring. NOTE: Use a shop cloth to protect the transmission case surface. 9. Remove the manual lever shaft retaining pin. 10. Remove the nut and slide the manual control lever shaft out of the case. 11. Remove the parking lever actuating rod. 1. Remove the manual valve detent lever. 2. Remove the parking lever actuating rod. CAUTION: Use care not to damage the manual control lever shaft bore. New seal may leak due to damage to the bore. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4679 12. Remove the manual control lever shaft seal. Installation 1. Use (A) Shift Lever Seal Replacer to install the (B) manual control lever seal. 2. Install the parking lever actuating rod. 1. Install the parking lever actuating rod. 2. Install the manual valve detent lever. 3. Install the manual control lever shaft. 1. Install the manual control lever shaft. 2. Install the nut. 3. Install the manual lever shaft retaining pin. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4680 4. Install the manual valve detent lever spring. 1. Position the manual valve detent lever spring. 2. Install the bolt. 5. Install the digital TR sensor. 1. Install the digital TR sensor. 2. Loosely install the bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use the digital TR Sensor Alignment Tool to align the digital TR sensor slots. The tool is designed to fit snug. 7. Tighten the bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4681 8. With manual lever in overdrive, connect the shift control cable. 9. Install the digital TR sensor electrical connector. 10. Install the filter and transmission fluid pan. 11. Lower the vehicle. 12. Connect the battery ground cable. 13. If equipped reactivate the air suspension.. 14. Fill the transmission with fluid and inspect for proper operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4682 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications Shift Cable Bracket 10 ft.lb Shift Cable Nut 22 ft.lb Transmission Shift Cable 17 - 23 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4686 Shift Cable: Adjustments 1. Place the selector lever in the OD position. ^ Place 1.36 Kg (3 lbs.) weight on the selector lever. 2. Raise and support the vehicle. 3. Disconnect the shift cable and bracket from the manual control lever. 4. Place the manual control lever in the OD position. 5. Connect the transmission shift cable to the manual control lever, 6. Lower the vehicle. 7. Remove the 1.36 Kg (3 lbs.) weight. 8. Carefully move the manual control lever from detent to detent and compare with transmission settings. Verify that the vehicle will start in PARK or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated and include Digital Transmission Range (DTR) sensor AM adjustment in NEUTRAL. ^ Re-adjust if necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4687 Shift Cable: Service and Repair Removal 1. Disconnect the transmission shift cable from the steering column. 1. Disconnect the transmission shift cable from the transmission selector lever arm and support. 2. Disconnect the transmission shift cable from the steering column instrument panel bracket. 2. Disconnect the cable shift actuator cable fitting. 3. Push the rubber grommet and transmission shift cable through the bulkhead. 4. Raise and support the vehicle. 5. Remove the shift cable and bracket from the automatic transmission. 1. Disconnect the transmission shift cable from the manual control lever. 2. Disconnect the shift actuator cable fitting to release the transmission shift cable and disconnect the transmission shift cable from the transmission shift cable bracket. 6. Remove the transmission shift cable bracket from the transmission. 1. Remove the bolts. 2. Remove the bracket. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4688 1. To install, reverse the removal procedure. ^ Adjust the shift cable. 2. Use new shift actuator cable fittings at the transmission selector lever arm and support and the transmission shift cable bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip Sun Gear: Technical Service Bulletins A/T - 4R70W Needle Bearing/Race Kit Service Tip Article No. 03-26-1 01/12/04 TRANSMISSION - 4R70W - NEW SERVICE PART - NUMBER 5 NEEDLE BEARING AND RACE KIT - SERVICE TIP FORD: 1994-1997 THUNDERBIRD, 1994-2003 CROWN VICTORIA, MUSTANG, E SERIES 1996-2001 EXPLORER 1994-2003 F SERIES LINCOLN: 1994-1998 MARK VIII 1994-2003 TOWN CAR MERCURY: 1994-1997 COUGAR 1994-2003 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE Should repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants all must be replaced in combination. A mismatch of service parts may cause an internal noise or a loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of service pants. This new kit services all 4R70W transmissions built prior to the 2004 model. ACTION A new Service Kit 4L3Z-7D234-M has been produced to eliminate the mismatch of service parts. The kit contains the following: ^ A new two (2) piece number five (# 5) thrust bearing assembly (70234 bearing and 70235 race) (Figure 1) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4693 ^ A forward clutch sun gear (7A399) (Figure 2) ^ A reverse sun gear (7A019) (Figure 3) SERVICE TIP To install, refer to the latest version Workshop Manual for disassembly and reassembly of the transmission. CAUTION ALL COMPONENTS IN THE KIT MUST BE INSTALLED OR THE REPAIR MAY NOT BE EFFECTIVE AND MAY CAUSE AN INTERNAL NOISE OR LOSS OF FORWARD AND~OR REVERSE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4694 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip Thrust Washer/Bearing: Technical Service Bulletins A/T - 4R70W Needle Bearing/Race Kit Service Tip Article No. 03-26-1 01/12/04 TRANSMISSION - 4R70W - NEW SERVICE PART - NUMBER 5 NEEDLE BEARING AND RACE KIT - SERVICE TIP FORD: 1994-1997 THUNDERBIRD, 1994-2003 CROWN VICTORIA, MUSTANG, E SERIES 1996-2001 EXPLORER 1994-2003 F SERIES LINCOLN: 1994-1998 MARK VIII 1994-2003 TOWN CAR MERCURY: 1994-1997 COUGAR 1994-2003 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE Should repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants all must be replaced in combination. A mismatch of service parts may cause an internal noise or a loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of service pants. This new kit services all 4R70W transmissions built prior to the 2004 model. ACTION A new Service Kit 4L3Z-7D234-M has been produced to eliminate the mismatch of service parts. The kit contains the following: ^ A new two (2) piece number five (# 5) thrust bearing assembly (70234 bearing and 70235 race) (Figure 1) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4699 ^ A forward clutch sun gear (7A399) (Figure 2) ^ A reverse sun gear (7A019) (Figure 3) SERVICE TIP To install, refer to the latest version Workshop Manual for disassembly and reassembly of the transmission. CAUTION ALL COMPONENTS IN THE KIT MUST BE INSTALLED OR THE REPAIR MAY NOT BE EFFECTIVE AND MAY CAUSE AN INTERNAL NOISE OR LOSS OF FORWARD AND~OR REVERSE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4700 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Torque Converter Drain Plug 21 - 22 ft.lb Torque Converter Nuts 20 - 33 ft.lb Stall Speed Min 2336 Max 2718 End Play New or Rebuilt 0.014 - 0.041 in Used 0.119 - 0.123 in Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4704 Torque Converter: Description and Operation The torque converter transmits and multiplies torqued. The torque converter is a four-element device: ^ impeller assembly ^ turbine assembly ^ reactor assembly ^ clutch and damper assembly The standard torque converter components operate as follows: ^ Rotation of the converter housing and impeller set the fluid in motion. ^ The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft. ^ The reactor redirects fluid going back into the impeller, allowing for torque multiplication. ^ The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency. ^ Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis Torque Converter: Testing and Inspection Diagnosis Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the Customer's Concern. 3. Verify the Condition - Perform the Torque Converter Operation Test. 4. Perform Diagnostic Procedures. ^ Run on-board diagnostics. ^ Repair all non-transmission related Diagnostic Trouble Codes (DTCs) first. ^ Repair all transmission DTCs. ^ Rerun on-board diagnostic to verify repair. ^ Perform Line Pressure Test. ^ Perform Stall Speed Test. ^ Perform Diagnostic Routines. ^ Use the Diagnosis by Symptom Index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and repair as required before changing the torque converter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4707 Torque Converter: Testing and Inspection End Play Check 1. Insert End Play Checking Tool into the torque converter pump drive. 1. Position End Play Checking Tool. 2. Tighten the inner post until the tool is securely locked. 2. Attach Dial Indicator With Bracketry to End Play Checking Tool. ^ Position the dial indicator bottom on the converter pump drive hub and zero the dial. 3. Lift up on End Play Checking Tool and note the dial indicator reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4708 ^ If the reading exceeds end play limits, replace the torque converter. 4. Remove the dial indicator and tool. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4709 Torque Converter: Testing and Inspection Leakage Checks Special Tools 1. Clean the outside surface of the torque converter. 2. Install Torque Converter Leak Check Tool and Gasket into convert hub. WARNING: Always follow proper safety procedures while using press. 3. Install the torque converter with the installed leak check tool into the Arbor press. Secure the press. Apply enough force from the press to seal tool into the torque converter. NOTE: Use clean dry shop air. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4710 4. Apply air pressure to valve on leak check tool. 5. With air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap bubble solution may be applied around those areas to aid in diagnosis. If leaks are present, replace converter. 6. Remove air hose. Release pressure and then slowly release press. Remove converter. Remove tool. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4711 Torque Converter: Testing and Inspection One-Way Clutch Check Special Tools 1. Insert Converter Clutch Holding Tool in one of the grooves in the stator thrust washer. 2. Install Converter Clutch Torquing Tool in the converter pump drive. 3. Use a (A) torque wrench to turn (B) Converter Clutch Torquing Tool counterclockwise while holding the (C) Converter Clutch Holding Tool. ^ The converter should lock up and hold torque. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4712 ^ The torque converter one-way clutch should rotate freely in the clockwise direction. ^ Try the clutch for lockup and hold in at least five positions. ^ If the torque converter fails the lockup test torque, replace the torque converter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4713 Torque Converter: Testing and Inspection Diagnosis Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the Customer's Concern. 3. Verify the Condition - Perform the Torque Converter Operation Test. 4. Perform Diagnostic Procedures. ^ Run on-board diagnostics. ^ Repair all non-transmission related Diagnostic Trouble Codes (DTCs) first. ^ Repair all transmission DTCs. ^ Rerun on-board diagnostic to verify repair. ^ Perform Line Pressure Test. ^ Perform Stall Speed Test. ^ Perform Diagnostic Routines. ^ Use the Diagnosis by Symptom Index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and repair as required before changing the torque converter. End Play Check 1. Insert End Play Checking Tool into the torque converter pump drive. 1. Position End Play Checking Tool. 2. Tighten the inner post until the tool is securely locked. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4714 2. Attach Dial Indicator With Bracketry to End Play Checking Tool. ^ Position the dial indicator bottom on the converter pump drive hub and zero the dial. 3. Lift up on End Play Checking Tool and note the dial indicator reading. ^ If the reading exceeds end play limits, replace the torque converter. 4. Remove the dial indicator and tool. Leakage Checks Special Tools 1. Clean the outside surface of the torque converter. 2. Install Torque Converter Leak Check Tool and Gasket into convert hub. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4715 WARNING: Always follow proper safety procedures while using press. 3. Install the torque converter with the installed leak check tool into the Arbor press. Secure the press. Apply enough force from the press to seal tool into the torque converter. NOTE: Use clean dry shop air. 4. Apply air pressure to valve on leak check tool. 5. With air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap bubble solution may be applied around those areas to aid in diagnosis. If leaks are present, replace converter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4716 6. Remove air hose. Release pressure and then slowly release press. Remove converter. Remove tool. One-Way Clutch Check Special Tools 1. Insert Converter Clutch Holding Tool in one of the grooves in the stator thrust washer. 2. Install Converter Clutch Torquing Tool in the converter pump drive. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4717 3. Use a (A) torque wrench to turn (B) Converter Clutch Torquing Tool counterclockwise while holding the (C) Converter Clutch Holding Tool. ^ The converter should lock up and hold torque. ^ The torque converter one-way clutch should rotate freely in the clockwise direction. ^ Try the clutch for lockup and hold in at least five positions. ^ If the torque converter fails the lockup test torque, replace the torque converter. Operation Test 1 Of 2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4718 2 Of 2 This test verifies that the torque converter clutch control system and the torque converter are operating properly. 1. Perform Quick Test. Check for Diagnostic Trouble Codes (DTCs). 2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in OD position. 4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot. 5. Engine rpm should increase when brake pedal is tapped, and decrease about five seconds after pedal is released. If this does not occur, refer to Torque Converter Operation Concerns in the Diagnosis by Symptom Chart. 6. If the vehicle stalls in OD or manual 2 at idle with vehicle at a stop, move the transmission range selector lever to manual 1 position. If the vehicle stalls, refer to Torque Converter Operation Concerns in the Diagnosis by Index. Repair as required. If the vehicle does not stall in OD, refer to Diagnosis by Symptom. 7. If the vehicle exhibits a vibration during the road test complete the Road Test Evaluation Form. This form will aid the technician in determining the source of the vibration. NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as torque converter clutch shudder. a. spark plugs - check for cracks, high resistance or broken insulators b. plug wires c. fuel injector filter may be plugged d. fuel contamination - poor engine performance e. EGR valve - valve may let in too much exhaust gas and cause engine to run lean f. vacuum leak - engine will not get proper air/fuel mixture g. MAP/MAF sensor - improper air/fuel mixture h. H02S sensor - too rich/lean air/fuel mixture i. fuel pressure - may be too low j. engine mounts -loose/damaged mounts can cause vibration concerns k. axle joints - check for vibration Stator to Impeller Interference Check NOTE: Front pump support may remain in front pump support and gear during this test. 1. Position the front pump support with the splines up. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4719 2. Mount (A) torque converter on the (B) front pump support with the splines on the one-way clutch inner race, engaging the mating splines of the front pump support. 3. Hold the (A) front pump support stationary and rotate the (B) torque converter counterclockwise. ^ The torque converter should rotate freely with no signs of scraping. ^ If there are signs of scraping, replace the torque converter. Stator to Turbine Interference Check NOTE: Front pump support may remain in front pump support and gear during this test. 1. Position the torque converter with the pump drive up. 2. Install the (A) front pump support to engage the mating splines of the front pump support shaft on the (B) torque converter. 3. Install the forward clutch cylinder and shaft engaging the splines with the rear clutch hub. 4. Check for stator to turbine interference. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 4720 1. Hold the front pump support stationary. 2. Attempt to rotate the forward clutch cylinder and shaft. ^ The turbine and torque converter clutch assemblies should rotate in both directions not exceeding maximum torque of 9.5 Nm (7 ft. lbs.) without any signs of metallic interference or scraping noise. 5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine. In such cases, the torque converter must be replaced. ^ The converter crankshaft pilot should be checked for nicks or damaged surfaces that could cause interference when installing the torque converter into the crankshaft. Check the converter front impeller hub for nicks or sharp edges that would damage the pump seal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Cleaning and Inspection Torque Converter: Service and Repair Cleaning and Inspection 1. If the torque converter is being replaced, continue with Substep 2 of Step 2. 2. If the torque converter is not being replaced, the following procedures must be performed: 1. The torque converter must be thoroughly cleaned. ^ Torque converters with drain plugs can be cleaned by using Torque Converter/Oil Cooler Cleaner. ^ Torque converters without drain plugs can be cleaned by hand. Partially fill the torque converter using only recommended transmission fluid for the applicable transmission. Hand agitate the torque converter and then thoroughly drain the fluid. Refill the torque converter with new fluid specified for transmission, and reinstall. 2. All cooler tubes must be thoroughly cleaned by backward and forward flushing. 3. If the cooler is to be replaced, use only factory approved service parts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Cleaning and Inspection > Page 4723 Torque Converter: Service and Repair Flushing Special Tools NOTE: When the transmission has been repaired for internal damage the torque converter must be cleaned using a mechanically agitated cleaner. 1. Use Torque Converter/Oil Cooler Cleaner to clean and flush the torque converter. 2. After flushing, drain the remainder of the solvent. 3. Add 1.9 liter (2 qt.) of clean transmission fluid to the converter and agitate by hand. 4. Thoroughly drain the solution. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Cleaning and Inspection > Page 4724 Torque Converter: Service and Repair Service and Replacement 1. The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on complete diagnostic procedures. ^ Converter studs (S), impeller hub or bushing are damaged. ^ Discoloration (due to overheating). ^ The torque converter is found to be out of specification when performing one of the following torque converter checks: ^ One-Way Clutch Check ^ End Play Check ^ Stator to Turbine Interference Check ^ Stator to Impeller Interference Check ^ Torque Converter Leak Check ^ Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes: ^ Major Metallic Failure ^ Multiple Clutches or Clutch Plate Failures ^ Sufficient Component Wear which results in Metallic Contamination Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Page 4725 Torque Converter: Tools and Equipment Special Tools Special Tools Special Tools Special Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications Transmission Cooler: Specifications Transmission Fluid Cooler Mounting Bolts 12 - 14 ft.lb Cooler Clip-to-Frame Bolt 7 - 9 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4732 Transmission Cooler: Description and Operation The transmission fluid cooler is an Oil-To-Air (OTA) fluid cooler with a thermostatic bypass valve. The fluid cooler is mounted between the radiator and the condenser. ^ When the transmission fluid is cold and the thermostatic valve is closed, the transmission fluid does not circulate through the fluid cooler. ^ As the transmission fluid temperature increases, the thermostatic bypass valve opens and allows the transmission fluid to circulate through the fluid cooler. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Flow of Diagnosis Transmission Cooler: Flow of Diagnosis When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and OTA fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is but back into service. The OTA fluid cooler is not serviceable with existing equipment due to the thermostatic bypass valve, it must be replaced. When fluid leakage is found in the fluid cooler, replace the fluid cooler. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4735 Transmission Cooler: Initial Inspection and Diagnostic Overview When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and OTA fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is but back into service. The OTA fluid cooler is not serviceable with existing equipment due to the thermostatic bypass valve, it must be replaced. When fluid leakage is found in the fluid cooler, replace the fluid cooler. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4736 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Backflushing and Cleaning Transmission Cooler: Service and Repair Backflushing and Cleaning 1. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and OTA fluid cooler. These contaminants are a major cause of recuffing transmission concerns and must be removed from the system before the transmission is but back into service. The OTA fluid cooler is not serviceable with existing equipment due to the thermostatic bypass valve. 2. The OTA fluid cooler must be replaced under the following conditions: ^ major metallic failure. ^ multiple clutches or clutch plate failure. ^ sufficient component wear that results in metallic contamination. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Backflushing and Cleaning > Page 4739 Transmission Cooler: Service and Repair Removal and Installation Removal 1. Remove the cover. 2. Remove the battery. 3. Remove the air filter assembly. 4. Disconnect the fluid cooler tube and the fluid cooler outlet tube at the transmission fluid cooler. Plug the fluid cooler outlet tube and the fluid cooler inlet tube to prevent contamination. 5. Disconnect the power steering cooler lines at the fluid cooler. Plug the power steering cooler lines to prevent contamination. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Backflushing and Cleaning > Page 4740 6. Remove the upper radiator mounts. 7. Remove the bolts and remove the fluid cooler. Installation 1. Install the fluid cooler. ^ Position the fluid cooler. ^ Install the screws. 2. Install the upper radiator mounts and bolt Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Backflushing and Cleaning > Page 4741 3. Connect the power steering lines to the fluid cooler. 4. Connect the fluid cooler inlet tube and the fluid cooler outlet tube to the fluid cooler. 5. Fill the power steering reservoir. 6. Install the air filter assembly. 7. Install the battery. 8. Fill the transmission fluid to the proper level using Motorcraft MERCON (R) V Automatic Transmission fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Inspect for leaks. 9. Install the radiator cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4745 Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4746 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4751 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4752 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4753 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4754 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4755 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4756 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4757 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4758 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4759 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4760 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4761 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4762 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4763 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4764 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4765 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4766 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4767 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4768 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4769 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4770 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4771 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4772 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4773 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4774 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4775 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4776 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4777 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4778 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4779 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4780 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4781 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4782 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4783 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4784 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4785 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4786 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4787 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4788 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4789 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4790 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4791 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4792 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4793 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4794 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4795 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4796 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4797 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4798 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4799 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4800 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4801 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4802 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4803 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4804 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4805 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4806 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4807 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4808 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4809 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4810 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4811 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4812 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4813 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4814 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4815 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4816 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4817 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4818 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4819 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4820 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4821 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4822 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4823 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4824 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4825 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4826 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4827 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4828 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4829 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4830 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4831 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4832 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4833 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4834 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4835 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4836 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4837 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4838 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4839 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4840 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4841 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4842 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4843 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4844 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4845 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 4846 Transmission Mount: Specifications Rear Transmission Support Crossmember Bolts 35 - 46 ft.lb Transmission Mount Nuts 25 - 34 ft.lb Transmission Mount Bolts 50 - 68 ft.lb Rear Insulator Bolts 58 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Insulator and Retainer Transmission Mount: Service and Repair Transmission Insulator and Retainer Removal 1. Remove transmission support crossmember. 2. Remove the nuts from the transmission support insulator and remove the transmission support insulator. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Insulator and Retainer > Page 4849 Transmission Mount: Service and Repair Transmission Support Crossmember Removal 1. Deactivate the air suspension 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Remove the exhaust system. 5. Support the transmission with a suitable jack. 6. Remove the transmission support crossmember. 1. Remove the nuts retaining the transmission support insulator to the transmission support crossmember. 2. Remove the bolts retaining the transmission support crossmember to the body brackets. Remove the transmission support crossmember. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4853 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4854 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Loosen the digital Transmission Range (TR) bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4855 7. Tighten the bolts. 8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR sensor electrical connector. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4856 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Specifications Transmission Pressure Test Port: Specifications Pressure Tap Plugs ............................................................................................................................. ......................................... 8-16 Nm (71-141 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4863 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications Valve Body: Specifications Main Control Valve Body Bolts 80 - 97 in.lb Main Control Valve Body Cover Plate Bolts 80 - 97 in.lb Main Control Valve Body Separator Plate Bolts 80 - 97 in.lb Manual Control Valve Detent Lever Spring Bolt 62-97 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4867 Valve Body: Service and Repair Removal 1. Disconnect battery ground cable. 2. Raise and support the vehicle. 3. Drain transmission fluid and remove the transmission fluid pan and filter. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 4. Disconnect the molded lead frame from the solenoids. 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC). 3. Disconnect the electronic pressure control (EPC) solenoid0 4. Disconnect the bulkhead inter-connector. 5. Remove the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 1. Remove the bolts. 2. Remove the shift solenoid and the Torque Converter Clutch (TCC) solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4868 6. Remove the manual control valve detent lever spring. 1. Remove the bolt. 2. Remove the manual control valve detent lever spring. 7. Remove the 23 valve body to case bolts. 8. Remove the main control valve body and discard the pump outlet screen. Installation NOTE: Make sure that the drive pin of the manual valve detent lever assembly engages the manual valve in the proper location prior to installing the bolts. 1. Position the main control valve body gasket and main control valve body using the two alignment bolts as a guide. NOTE: The main control valve body bolts will be tightened in later steps. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4869 2. Loosely install the bolts. NOTE: The main control valve body bolts will be tightened in later steps. 3. Loosely install the bolts. 4. Install the manual control valve detent lever spring. 1. Position the manual control valve detent lever spring. 2. Install the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4870 5. Tighten the main control valve body bolts in the sequence shown. 6. Install the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 1. Install the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 2. Install the bolts. 7. Connect the molded lead frame to the solenoids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4871 ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. CAUTION: If installing a new filter, and the grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore. NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and seal. 8. Replace fluid filter and seal as required. 9. Position the (B) pan magnet into the (A) transmission fluid pan. NOTE: The pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. 10. Install the transmission fluid pan. 1. Position the transmission fluid pan gasket. 2. Position the transmission fluid pan. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4872 11. Install the bolts. 12. Lower the vehicle. 13. Connect the battery ground cable. 14. Fill the transmission with fluid and check for proper operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored Wiring Harness: Customer Interest A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored Article No. 99-19-7 09/20/99 ^ LAMP - INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ LAMP - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R7OW - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 FORD: 1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1999 TOWN CAR MERCURY: 1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to include additional vehicles and to correct the Service Procedure. ISSUE Intermittent Transmission Control Indicator Lamp (TCIL) or Malfunction Indicator Lamp (MIL) illumination may occur on some vehicles. The following Diagnostic Trouble Codes (DTCs) may be stored in memory: P0741, P0750, P0755, and P1746. This may be caused by the solenoid interconnect molded lead frame not being fully seated or the bulkhead interconnect clips not being fully seated between the solenoid interconnect molded lead frame and bulkhead interconnect. ACTION Verify the solenoid interconnect molded lead frame (-7G276-) is fully seated. If no concern is found, then inspect the bulkhead interconnect terminals for spread and/or not fully recessed. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnosis for DTCs retrieved as outlined in the appropriate 1999 Workshop Manual. If root cause is not determined, continue with this TSB. 2. Remove the transmission oil pan per the appropriate model Workshop Manual, Section 307-01. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4881 3. Verify that the solenoid interconnect molded lead frame is fully seated on all the solenoid connectors (Figure 1). If the solenoid interconnect molded lead frame is fully seated, then gently remove the solenoid interconnect molded lead frame, valve body, and bulkhead interconnect (-7G276-) per the appropriate model Workshop Manual, Section 307-01. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4882 4. With the bulkhead interconnect removed, push down on the terminal cover and check to see if any of the terminals are slightly protruding above the plastic cover (Figure 2). Gently pry off the terminal cover using a small screwdriver (Figure 3). With the terminal cover off, inspect the bulkhead interconnect for spreading terminals (Figure 4). If the bulkhead interconnect terminals are spread or slightly protruding above the plastic cover, replace with a new Bulkhead Interconnect (F8AZ-7G276-AA). 5. Reassemble. PART NUMBER F8AZ-7G276-AA Bulkhead Interconnect F8AZ-7G276-BA Solenoid Interconnect OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4883 OPERATION DESCRIPTION TIME 991907A Perform Inspection And 1.3 Hrs. Replace Bulkhead Interconnect DEALER CODING CONDITION BASIC PART NO. CODE 7G276 42 OASIS CODES: 206000, 501000, 502000, 504000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored Wiring Harness: All Technical Service Bulletins A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored Article No. 99-19-7 09/20/99 ^ LAMP - INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ LAMP - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R7OW - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 FORD: 1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1999 TOWN CAR MERCURY: 1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to include additional vehicles and to correct the Service Procedure. ISSUE Intermittent Transmission Control Indicator Lamp (TCIL) or Malfunction Indicator Lamp (MIL) illumination may occur on some vehicles. The following Diagnostic Trouble Codes (DTCs) may be stored in memory: P0741, P0750, P0755, and P1746. This may be caused by the solenoid interconnect molded lead frame not being fully seated or the bulkhead interconnect clips not being fully seated between the solenoid interconnect molded lead frame and bulkhead interconnect. ACTION Verify the solenoid interconnect molded lead frame (-7G276-) is fully seated. If no concern is found, then inspect the bulkhead interconnect terminals for spread and/or not fully recessed. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnosis for DTCs retrieved as outlined in the appropriate 1999 Workshop Manual. If root cause is not determined, continue with this TSB. 2. Remove the transmission oil pan per the appropriate model Workshop Manual, Section 307-01. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4889 3. Verify that the solenoid interconnect molded lead frame is fully seated on all the solenoid connectors (Figure 1). If the solenoid interconnect molded lead frame is fully seated, then gently remove the solenoid interconnect molded lead frame, valve body, and bulkhead interconnect (-7G276-) per the appropriate model Workshop Manual, Section 307-01. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4890 4. With the bulkhead interconnect removed, push down on the terminal cover and check to see if any of the terminals are slightly protruding above the plastic cover (Figure 2). Gently pry off the terminal cover using a small screwdriver (Figure 3). With the terminal cover off, inspect the bulkhead interconnect for spreading terminals (Figure 4). If the bulkhead interconnect terminals are spread or slightly protruding above the plastic cover, replace with a new Bulkhead Interconnect (F8AZ-7G276-AA). 5. Reassemble. PART NUMBER F8AZ-7G276-AA Bulkhead Interconnect F8AZ-7G276-BA Solenoid Interconnect OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4891 OPERATION DESCRIPTION TIME 991907A Perform Inspection And 1.3 Hrs. Replace Bulkhead Interconnect DEALER CODING CONDITION BASIC PART NO. CODE 7G276 42 OASIS CODES: 206000, 501000, 502000, 504000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Specifications Carrier Bearings: Specifications Differential Bearing Cap Bolt ............................................................................................................... ................................................. 105 Nm (77 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications Differential Case: Specifications Differential Case Maximum Runout ................................................................................................................................................. 0.076 mm (0.003 inch) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation Differential Case: Service and Repair Removal and Installation Removal 1. Remove the axle shafts. 2. Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage. 3. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4902 4. Position the special tool and inspect ring gear backlash and ring gear backface runout. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. Mark the bearing cap position before removal. 5. Loosen the differential case. 1. Remove the four bearing cap bolts. 2. Remove the two bearing caps. WARNING: Be careful not to allow the differential case to fall. CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage. 6. Use the pry bar and the wood block to remove the differential case from the rear axle housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4903 7. Remove the 10 ring gear bolts. CAUTION: Care should be taken not to damage the ring bolt hole threads. 8. Insert a punch in the bolt holes, and drive off the ring gear. 9. Install the differential case. Position the differential case assembly, including the bearing cups and shims, in the rear axle housing. Install the differential bearing caps and the differential bearing cap bolts. 10. Position the special tool. 1. Rotate the differential case to make sure the differential bearings are correctly seated. 2. Position the special tool. NOTE: If runout is less than the specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install new both the differential case and the differential bearings. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4904 11. Measure the differential case runout without the ring gear. 1. Rotate the differential case. 2. Check and note the differential case runout. 12. Remove the differential case from the rear axle housing and remove the differential bearings using the special tools. 13. Using the special tool install the new differential bearings on the differential case. 14. Position the differential case assembly, including the bearing cups and shims in the rear axle housing. ^ Tighten bearing caps to specification. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4905 15. Measure the differential case runout without the ring gear. ^ Check the case runout again with the new differential bearings. ^ If the runout is now less than the specification shown, use the new differential bearings for assembly. ^ If the runout is still excessive, the differential case is damaged and must be installed new. Installation CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned. 1. Press the ring gear on the differential case. 2. Install the ring gear bolts. ^ Apply Stud and Bearing Mount EOAZ- 19554-BA or equivalent meeting Ford specification WSK-M2G349-A I to ring gear bolts. 3. With pinion depth set and pinion installed, place the differential case in the rear axle housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4906 4. Install a shim on the left side. CAUTION: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated. 5. Install the left bearing cap and loosely install the bearing cap bolts. 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4907 8. Rotate the differential case to make sure it rotates freely. 9. Using the special tool measure the ring gear backlash. ^If the backlash is within specification, go to Step 14. The specification shown is the full allowable range. ^ If a zero back] ash condition occurs, go to Step 10. ^ If the backlash is not within specification, go to Step 11. 10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Check the backlash. Repeat Step 9. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4908 11. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown. ^ If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount. 12. Rotate the differential several times to make sure the differential bearings are correctly seated. 13. Using the special tool recheck the backlash. ^ If the backlash is within specification, go to Step 14. If the backlash is not within specification, repeat Step 9. ^ The specification shown is the full allowable range. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4909 14. Remove the bearing caps and bolts. ^ To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. ^ Using the special tool, make sure the differential bearing shims are fully seated and the assembly turns freely. 15. Install the bearing caps and bearing cap bolts. 16. Using the special tool recheck the backlash. ^ The specification shown is the full allowable range. 17. Install the axle shafts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4910 Differential Case: Service and Repair Disassembly and Assembly Differential Case and Ring Gear-Conventional Special Tools Disassembly 1. Remove the differential case. 2. Remove the 10 ring gear bolts. CAUTION: Care should be taken not to damage the bolt hole threads. 3. Insert a punch in the bolt holes and drive the ring gear off. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4911 4. Using the special tools remove the differential bearing, if required. 5. Remove the differential pinion shaft lock bolt. 6. Remove the differential pinion shaft. 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4912 8. Remove the differential side gears and the differential pinion thrust washers. Assembly 1. Use Thermally Stable Rear Axle Lubricant XY-80W90-QL meeting Ford specification WSP-M2C I 97-A to lubricate the differential side gear thrust washers and the differential side gear journals. Position the differential side gear thrust washers on the differential side gears. 2. Position the differential side gears. 3. Use Thermally Stable Rear Axle Lubricant XY-80W90-QL meeting Ford specification WSP-M2C197-A to lubricate the differential pinion thrust washers and the differential pinion gears and assemble. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4913 4. Engage the differential pinion gears opposite the differential side gears. 5. Rotate the differential pinion gears to align with the differential pinion shaft bore. 6. Insert the differential pinion shaft. ^ Align the hole in the differential pinion shaft with the hole in the differential case. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock(R) and Sealer EOAZ- 19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. 7. Install a new differential pinion shaft lock bolt and tighten finger-tight. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4914 8. Using the special tool install the new differential bearings on the differential case. NOTE: Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly. 9. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case. 10. Press the ring gear on the differential case. 11. Install the ring gear bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4915 Apply Stud and Bearing Mount EOAZ- I 9554-BA or equivalent meeting Ford specification WSK-M2G349-A I to ring gear bolts. 12. Install the differential case. Differential Case and Ring Gear-Traction-LOK(R) Disassembly 1. Remove the differential case. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4916 2. Remove the 10 ring gear bolts. CAUTION: Care should be taken not to damage the bolt hole threads. 3. Insert a punch in the bolt holes and drive the ring gear off. 4. Using the special tools remove the differential bearing. ^ Repeat for the other side. 5. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. WARNING: Due to the spring tension, care must be used when removing the differential clutch spring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4917 6. Remove the differential clutch spring. 7. Remove the differential gears. 1. Remove the two differential pinion gears. 2. Remove the two differential side gears. 3. Remove the two differential pinion thrust washers. CAUTION: Keep the differential clutch packs in order. Do not mix them. They must be reassembled in the same sequence. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4918 8. Remove the differential clutch packs and differential side gears and tag them "right" and "left" with the shim. ^ Clean and inspect the remaining parts of the differential case for wear or damage and install new parts as necessary. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. 9. Clean and inspect the differential clutch packs for wear and install new parts as necessary. Assembly CAUTION: 118 ml. ( 4. oz) of the specified Ford Friction Modifier must be used in the axle. 1. Prelubricate each steel clutch plate and soak all friction plates with additive Ford Friction Modifier C8AZ- 1913546-A or equivalent meeting Ford specification EST-M2C I 18-A for at least 15 minutes. CAUTION: Do not mix the differential clutch packs or shims from one side with the other. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4919 2. Assemble the differential clutch packs (without the shims) on the respective differential side gears. CAUTION: Make sure the correct mandrel is used with the special tool. 3. Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge. 4. Position the special tool hand-tight on top of the differential clutch pack. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4920 5. Install the special tool over the disc and differential clutch pack. 6. Install the nut of the gauge over the top and base stud. 7. Use a Feeler Gauge and select the thickest blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. 8. Remove the special tool from the clutch pack and side gear assembly. 9. Install the shim(s) on the clutch pack and side gear assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4921 10. Install the differential side gear in the differential case. 11. Install the differential pinion gears with differential pinion thrust washers in the differential case. 12. Install the differential clutch spring, using a soft-faced hammer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4922 13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight. 14. Using the special tool install the differential bearing on the differential case. ^ Repeat for the other side. 15. Check the torque required to rotate one differential side gear. ^ Mount the differential case and special tool in a vise. ^ The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary. NOTE: Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 4923 16. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case. 17. Press the ring gear on the differential case. 18. Install the ring gear bolts. ^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-Al to the ring gear bolts. 19. Install the differential case. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications Differential Cover: Specifications Torque Specifications Differential housing cover bolts ........................................................................................................................................................... 45 Nm (33 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 4927 Differential Cover: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. NOTE: Empty the lubricant into a clean container for reuse. 2. Remove the differential housing cover. 1. Remove the 10 differential housing cover bolts and drain the lubricant from the rear axle housing. 2. Remove the differential housing cover. Installation CAUTION: Make sure the machined surfaces on both 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. 1. Clean the gasket mating surface of the rear axle and the differential housing cover. 2. Apply a new continuous bead of sealant to the differential housing cover. ^ Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G 195-A. 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 properly cured. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 4928 3. Install the differential housing cover. 1. Install the differential housing cover. 2. Install the 10 differential housing cover bolts. CAUTION: For Traction-Lok(R) axles, first fill the rear axle with 118 ml. (4 oz.) of specified Ford Friction Modifier. NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the level shown in the illustration. 4. Fill the rear axle with 1.8 liters (3.75 pints) of Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2CI 97-A and install the filler plug. 5. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair Differential Axle Housing: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Mark the driveshaft flange and the pinion flange for correct alignment during installation. 3. Remove the four driveshaft retainer bolts and disconnect the driveshaft. 4. Remove the wheels and tires. 5. Remove the rear disc brake calipers from the brake adapters and brake discs, and wire the caliper out of the way. 6. Remove the rear brake discs. 7. Remove the parking brake rear cable and conduit from the parking brake cable equalizer. ^ Reroute the parking brake rear cable and conduit out of the way. ^ Repeat for the other side. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 4932 8. Remove the anti-lock brake sensors. ^ Reroute the anti-lock brake sensor wiring. 9. Remove the rear stabilizer bar from the rear stabilizer bar link and bushing. 10. Disconnect the rear stabilizer bar bracket bolts, the rear stabilizer bar brackets and the rear stabilizer bar. 11. If equipped with rear air springs, remove the height sensor. CAUTION: Take care not to damage the threads on the bellcrank stud. Separate the Watts linkage from the rear axle housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 4933 12. Remove the retainer nut from the bellcrank stud. WARNING: Use additional support straps to secure the rear axle to the jack. 13. Support the rear axle housing with a suitable jack. 14. Remove the shock absorber lower retainer nuts and remove the shock absorbers from the retainer brackets. 15. Remove the lower control arm retainer nut and bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 4934 16. Remove the upper control arm retainer nut and bolt. 17. Unseat the air springs and lower the rear axle from the vehicle. Installation WARNING: Use additional support straps to secure the rear axle to the high-lift transmissions jack. 1. Raise the rear axle into position using a high-lift transmission jack. ^ Seat the air springs. 2. Install the upper control arm retainer nut and bolt and tighten. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 4935 3. Install the lower control arm retainer nut and bolt and tighten. 4. Install the shock absorbers. ^ Position the shock absorbers into the retainer brackets, and tighten the retainer nuts and bolts. 5. Remove the high-lift transmission jack. 6. Install the Watts linkage on the rear axle housing. ^ Install the retainer nut on the bellcrank stud and tighten. 7. If equipped with rear air springs, install the height sensor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 4936 8. Install the rear stabilizer bar retainer bolts and tighten. 9. Install the rear stabilizer bar link and bushing retainer nuts and tighten. 10. Install the anti-lock brake sensors. 11. Install the parking brake rear cable and conduit into the parking brake cable equalizer. 12. Install the rear brake discs. 13. Install the rear disc brake calipers on the brake discs/brake adapters. 14. Install the wheels and tires. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 4937 15. Position the rear driveshaft and align the marks on the pinion flange. 16. Install the four driveshaft retainer bolts. 17. If equipped with rear air springs, turn on the air suspension switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications Fill Plug: Specifications Oil Filler Plug ....................................................................................................................................... .................................................... 30 Nm (22 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Capacity Standard Axle ...................................................................................................................................... .................................................................... 1.8 - 1.9L Traction-Lok Axle ................................................................................................................................. ................................................................. 2.2 - 2.4L Traction-Lok differentials add 4 oz of friction modifier C8AZ-19B956-A on refill. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4945 Fluid - Differential: Fluid Type Specifications Standard Applications Premium Rear Axle Lubricant SAE 80W90 Specification .................................................................... ........................................................................................................................... WSP-M2C197-A Police, Taxi, Limo Applications High Performance Rear Axle Lubricant SAE 75W140 Specification ................................................... ............................................................................................................................................ WSL-M2C192-A Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 4946 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications Pinion Bearing: Specifications Pinion bearing preload (used pinion bearings) 8 - 14 in.lb Pinion bearing preload (new pinion bearings) 16 - 29 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair Pinion Flange: Service and Repair Special Tools Removal NOTE: The rear wheels and rear brake discs must be removed to prevent brake drag during drive pinion bearing preload adjustment. 1. Remove the rear brake discs. 2. Mark the driveshaft flange and pinion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. ^ Position the driveshaft out of the way. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 4953 4. Install a Nm (inch-pound) torque wrench on the pinion nut and record the torque required to maintain rotation of the drive pinion gear through several revolutions. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. 5. Use Companion Flange Holding Tool to hold the pinion flange while removing the pinion nut. 6. Mark the driveshaft pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 7. Use a 2-Jaw Puller for Differential Case Bearings to remove the pinion flange. Installation 1. Lubricate the pinion flange splines. ^ Use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 4954 2. Align the pinion flange with the drive pinion shaft. 3. With the drive pinion in place in the rear axle housing, install the pinion flange using the Companion Flange Replacer. 4. Position the new pinion nut. CAUTION: Under no circumstances k the pinion nut to be backed off to reduce preload. If reduced preload is required, a new drive pinion collapsible spacer and pinion nut must be installed. 5. Use Companion Flange Holding Tool to hold the pinion flange while tightening the pinion nut. ^ Tighten the pinion nut, rotating the pinion occasionally to make sure the cone and roller bearings are seating property. Take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained by rotating the pinion with a Nm (inch-pound) torque wrench. ^ If the original recorded preload is lower than specifications, tighten to the specification for used bearings. If the preload is higher than specification, tighten the nut to the original, trial reading as recorded. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 4955 6. Position the rear driveshaft and align the mark on the pinion flange. 7. Install the four rear driveshaft to pinion flange bolts. 8. Install the rear brake discs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 4956 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair Pinion Gear: Service and Repair Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4960 Special Tools Special Tools Special Tools Removal 1. Remove the differential case. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4961 2. Mark the driveshaft flange and the pinion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. 4. Install a Nm (inch-pound) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. Remove the pinion flange and pinion nut. 6. Install the special tool and, with a soft-faced hammer, drive the pinion assembly out of the front bearing cone and remove it through the rear of the housing. ^ Remove the rear axle drive pinion seal. ^ Remove the rear axle drive pinion shaft oil slinger. NOTE: Remove the drive pinion collapsible spacer and discard it. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4962 7. Using the special tool remove the pinion bearing. NOTE: Do not remove the pinion bearing cups from the carrier casting unless the cups are damaged. 8. Remove the outer differential bearing cup with the special tools. 9. Remove the inner differential bearing cup with the special tools. Installation 1. Position the special tools and the inner and outer bearing cups in their respective bores. 1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner pinion bearing cup. 2. Place the special tool on the outer pinion bearing cup. 3. Install the special tool into the replacer tools. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4963 2. Tighten the Threaded Drawbar to seat the pinion bearing cups into their bores. 3. Drive the outer pinion bearing cup into the axle housing using the special tools. 4. Drive the inner pinion bearing cup into the axle housing using the special tools. CAUTION: Whenever the cups are replaced, the pinion bearings must also be replaced. NOTE: If a feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated. 5. Make sure the cups are correctly seated in their bores. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4964 6. Assemble and position the Pinion Depth Gauge. NOTE: This step duplicates final pinion bearing preload. 7. Tighten the special tool to the specification shown. NOTE: The special tool must be offset to obtain an accurate reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4965 8. Rotate the special tool several half-turns to make sure of correct seating of the pinion bearings and position the special tool. 9. Install the special tool. 1. Position the special tool. 2. Install the differential side bearing caps. 3. Install the four differential side bearing cap bolts. NOTE: ^ Drive pinion bearing adjustment shims must be flat and clean. ^ A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integral rear axle assemblies. 10. Use a drive pinion bearing adjustment shim as a gauge for shim selection. ^ After the correct shim thickness has been determined, remove the special tools. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4966 11. Using a press and the special tool press the pinion bearing and pinion shim until they are firmly seated on the pinion. 12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder 13. From inside the rear axle housing, install the drive pinion assembly (drive pinion, shims, rear bearing cone and roller, and drive pinion collapsible spacer) into the rear axle carrier bore. CAUTION: Installation without the proper tool can result in early seal failure. If the rear axle drive pinion becomes cocked during installation, remove it and install a new one. 14. Install a new rear axle drive pinion seal. 1. Install the front pinion bearing cone and roller. 2. Install the rear axle drive pinion shaft oil slinger in the rear axle housing. 3. Install the rear axle drive pinion seal on the Pinion Seal Replacer. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG- I -C or equivalent meeting Ford specification ESA-MIC75-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4967 15. Place the Pinion Seal Replacer in the rear axle drive pinion seal bore, and drive the rear axle drive pinion seal into place. 16. Lubricate the pinion flange splines. ^ Use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C I 97-A. NOTE: Disregard the scribe marks if a new pinion flange is being installed. 17. Align the pinion flange with the drive pinion shaft. 18. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool. 19. Position the new pinion nut. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new drive pinion collapsible spacer and pinion nut must be installed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4968 20. Use the special tool to hold the pinion flange while tightening the pinion nut. 21. Install the differential case in the rear axle housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4969 Pinion Gear: Tools and Equipment Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4970 Special Tools Special Tools Special Tools Special Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications Ring Gear: Specifications General Specifications Maximum back face ring gear runout ........................................................................................................................................... 0.102 mm (0.004 inch) Backlash between ring gear and pinion teeth .......................................................................................... 0.203-0.381 mm (0.305-0.381 mm preferred) ............................................................................................................................................. ................... 0.008-0.015 inch (0.012-0.015 inch preferred) Ring gear maximum backlash variation between teeth ................................................................................................................. 0.102 mm (0.004 inch) Ring gear bolts ................................................................................................................ ................................................................... 105 Nm (77 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair Seals and Gaskets: Service and Repair Special Tools Removal 1. Remove the pinion flange. 2. Using a screwdriver, force the metal flange of the rear axle drive pinion seal up and strike with a hammer. Install gripping pliers and remove. Installation 1. Lubricate the new rear axle drive pinion seal. ^ Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-MIC75-B. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and install a new seal. 2. Using the special tool install the rear axle drive pinion seal. 3. Install the pinion flange. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Page 4977 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair Axle Bearing: Service and Repair Special Tools Special Tools Removal 1. Remove the axle shaft. CAUTION: Never remove the inner wheel bearing oil seal by itself Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. 2. Use Impact Slide Hammer and Rear Axle Bearing Remover to remove the rear wheel bearing and inner wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. ^ Use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C I 97-A. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Page 4982 2. Use Axle Tube Bearing Replacer to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG- I -C or equivalent meeting Ford specification ESA-MIC75-B. 4. Use Axle Tube/Seal Replacer to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Page 4983 Axle Bearing: Tools and Equipment Special Tools Special Tools Special Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair Axle Shaft: Service and Repair Removal CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the rear wheel bearings. 1. Loosen the lug nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the lug nuts. WARNING: When equipped with rear air springs, the electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1. Remove the lug nuts. 2. Remove the wheel and tire assembly. ^ 4. Remove the differential housing cover. 1. Remove the 10 differential housing cover bolts and drain the lubricant from the rear axle housing. 2. Remove the differential housing cover. 5. Remove the rear brake anti-lock sensor. 6. Remove the brake discs. CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft can cause the differential pinion gears to fall out of the assembly. This can result in chipped or damaged components. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 4988 7. Remove the differential pinion shaft. 1. Remove the differential pinion shaft lock bolt. 2. Remove the differential pinion shaft. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. 8. Remove the U-washers. 1. Push the axle shafts inboard. 2. Remove the U-washers. 9. Reinstall the differential pinion shaft. 1. Install the differential pinion shaft. 2. Install the differential pinion shaft lock bolt finger-tight. CAUTION: Do not damage the inner wheel bearing oil seal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 4989 10. Remove the two axle shafts. Installation 1. Lubricate the lip of the inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG- I -C or equivalent meeting Ford specification ESA-MIC75-B. CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft can cause the differential pinion gears to fall out of the assembly. This can result in chipped or damaged components. 2. Remove the differential pinion shaft. 1. Remove the differential pinion shaft lock bolt. 2. Remove the differential pinion shaft. CAUTION: Do not damage the inner* r wheel bearing oil seal. 3. Install the two axle shafts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 4990 CAUTION: Do not damage the rubber O-rings in the U-washer grooves. 4. Install the U-washers. 1. Position the two U-washers on the button end of the axle shaft. 2. Pull the axle shafts outward to seat the U-washers in the side gears. 5. Install the differential pinion shaft. 1. Align the hole in the differential pinion shaft with the lock bolt hole. 2. Install the differential pinion shaft lock bolt. 6. Install the brake discs. 7. Install the rear brake anti-lock sensor. 8. Install the differential housing cover and fill the rear axle housing with 1.8 liters (3.75. pints) of Thermally Stable Rear Axle Lubricant XY-8OW90-QL or equivalent meeting Ford specification WSP-M2C197-A. WARNING: Always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheel or the surface of the wheel hub or rear brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. 9. Clean the wheel hub and mounting surfaces. NOTE: If equipped with air suspension, reactivate the system by turning the air suspension switch on. 10. Install the tire and wheel assembly. 1. Position the tire and wheel assembly. 2. Install the lug nuts and lower the vehicle. 3. Tighten the lug nuts. 4. Install the center cap. ^ Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4995 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4996 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4997 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4998 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4999 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5000 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5001 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5002 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5003 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5004 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5005 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5006 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5007 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5008 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5009 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5010 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5011 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5012 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5013 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5014 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5015 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5016 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5017 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5018 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5019 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5020 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5021 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5022 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5023 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5024 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5025 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5026 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5027 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5028 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5029 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5030 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5031 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5032 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5033 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5034 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5035 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5036 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5037 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5038 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5039 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5040 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5041 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5042 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5043 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5044 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5045 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5046 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5047 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5048 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5049 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5050 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5051 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5052 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5053 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5054 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5055 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5056 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5057 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5058 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5059 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5060 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5061 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5062 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5063 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5064 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5065 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5066 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5067 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5068 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5069 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5070 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5071 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5072 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5073 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5074 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5075 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5076 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5077 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5078 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5079 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5080 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5081 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5082 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5083 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5084 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5085 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5086 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5087 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5088 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5089 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5090 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5091 Wheel Bearing: Testing and Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, install a new wheel hub. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5092 Wheel Bearing: Service and Repair FRONT WHEEL HUB Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. Remove and discard the front hub cap grease seal. 5. CAUTION: The front axle wheel hub retainer must never be reused. If the retainer is reused, it can back off resulting in loss of the front wheel and or damage to the wheel hub and bearing assembly. Remove the front axle wheel hub retainer. Discard the retainer. 6. CAUTION: When removing the wheel hub and bearing, use caution not to damage the ABS sensor lead or the ABS sensor ring. NOTE: The wheel hub and bearing assembly is a slip fit design and should not require a puller to remove. Remove the wheel hub and bearing assembly. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5093 1. CAUTION: When installing the wheel hub and bearing, use extreme caution not to damage the ABS sensor lead or the ABS sensor ring. Install the wheel hub and bearing assembly. 2. Install a new front axle wheel hub retainer. 3. Install a new front hub cap grease seal. 4. Install the brake disc. 5. Install the wheel and tire assembly. 6. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Wheel Hub Retainer ........................................................................................................................................................... 300 Nm (221 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing Drive/Propeller Shaft: Customer Interest A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 5107 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 5108 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis Drive/Propeller Shaft: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis Article No. 01-1-14 01/22/01 ^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) ^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) FORD: 1999-2001 CROWN VICTORIA MERCURY: 1999-2001 GRAND MARQUIS ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph) which may be related to driveshaft, axle, wheels, or their components. ACTION Identify the causal component for the vibration and balance or replace as necessary to eliminate the vibration. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5114 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5115 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5116 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5117 For Dealerships with An Electronic Vibration Analyzer Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration conditions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5118 Driveline Vibration Data Sheet OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing Drive/Propeller Shaft: All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 5123 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 5124 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis Drive/Propeller Shaft: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis Article No. 01-1-14 01/22/01 ^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) ^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) FORD: 1999-2001 CROWN VICTORIA MERCURY: 1999-2001 GRAND MARQUIS ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph) which may be related to driveshaft, axle, wheels, or their components. ACTION Identify the causal component for the vibration and balance or replace as necessary to eliminate the vibration. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5130 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5131 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5132 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5133 For Dealerships with An Electronic Vibration Analyzer Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration conditions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5134 Driveline Vibration Data Sheet OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5135 Drive/Propeller Shaft: Specifications Drive shaft- to-drive shaft pinion flange bolts 70 - 95 ft.lb Driveshaft bolts 83 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5136 Drive/Propeller Shaft: Description and Operation All driveshaft assemblies are balanced. If the vehicle is to be undercoated, cover the driveshaft assembly to prevent overspray of any undercoating material. The driveshaft has the following features: ^ A tubular shaft used to transfer torque from the engine, through the transmission to the ring and pinion in the rear axle, which transmits the torque to the wheels. ^ Consists of two single cardan universal joints, a driveshaft slip-yoke and a driveshaft centering socket yoke. ^ The splined slip-yoke permits the driveshaft to move forward and rearward on the transmission output shaft during drivetrain movement. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5137 Drive/Propeller Shaft: Service and Repair Removal 1. Raise and support the vehicle. 2. Index-mark the driveshaft. ^ Place a paint index-mark on the pinion flange to the driveshaft centering socket yoke. 3. Remove the driveshaft-to-driveshaft pinion flange bolts. 4. Lower the driveshaft and slide the driveshaft rearward from the transmission output shaft. ^ Place a paint index-mark on the driveshaft slip-yoke to the transmission output shaft. ^ Plug the extension housing to prevent fluid loss. Installation NOTE: ^ Inspect the extension housing seal for damage, install new as necessary. ^ Lubricate the slip-yoke spline with Premium Long-Life Grease XG- I -C or -K or equivalent meeting Ford specification ESA-M I C75-13. ^ Install the driveshaft so that the index-marks made on the transmission output shaft to the driveshaft slip-yoke and the index-marks made on the pinion flange to the driveshaft centering socket yoke are aligned. ^ If installing a new driveshaft, align the factory-made yellow paint mark at the rear of the driveshaft tube with the factory-made yellow paint mark on the pinion flange. If the paint marks are not visible. 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 have the following: ^ A lubed-for-life design. ^ Nylon thrust washers, located at each base of the bearing cup, which control end play, position the needle bearings and improve grease movement. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 5141 Universal Joint: Service and Repair Special Tools Disassembly CAUTION: Do not clamp the driveshaft in the jaws of a vice or a similar holding fixture. 1. Place the driveshaft on a suitable workbench. NOTE: Mark the positions of the driveshaft components relative to the driveshaft tube. This ensures all components are reassembled in the same relationship to maintain correct balance. 2. Index the driveshaft and driveshaft components. 3. Clamp the U-Joint Tool in a vise. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 5142 4. Remove the snap rings. NOTE: If the bearing cup cannot be pressed all the way out, remove it with vise grips. 5. Remove the driveshaft slip-yoke. 1. Position the driveshaft in the U-Joint Tool. 2. Press out a bearing cup. 3. Rotate the driveshaft 180 degrees. 4. Press on the spider to remove the bearing cup from the opposite side. 5. Remove the driveshaft slip-yoke. 6. Remove the remaining bearing cups and the spider. 7. Remove the snap rings from the driveshaft centering socket yoke end. NOTE: If the bearing cup cannot be pressed all the way out, remove it with vise grips. 8. Remove the driveshaft centering socket yoke. 1. Position the driveshaft in the U-Joint Tool. 2. Press out a bearing cup. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 5143 3. Rotate the driveshaft 180 degrees. 4. Press on the spider to remove the bearing cup from the opposite side. 5. Remove the driveshaft centering socket yoke. 9. Remove the remaining bearing cups and the spider. 10. Clean the driveshaft yoke area at each end of the driveshaft. ^ Inspect the driveshaft and driveshaft components for wear or damage. Assembly NOTE: Universal joint service kits are to be installed as complete assemblies only. Do not use components from other universal joints. 1. Install a new bearing cup. 1. Start a new bearing cup into the driveshaft yoke. 2. Position a new spider in the driveshaft yoke. 3. Install the driveshaft into the U-Joint Tool. 4. Press the bearing cup below the yoke surface. NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing the yellow snap rings, install the black snap rings also supplied in the kit. 2. Remove the driveshaft from the U-Joint Tool and install the snap ring. 3. Repeat Steps 1 and 2 for the opposite side. 4. Install a new bearing cup. 1. Start a new bearing cup into the driveshaft centering socket yoke. 2. Install the driveshaft into the U-Joint Tool. 3. Press the bearing cup below the yoke surface. NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing the yellow snap rings, install the black snap rings also supplied in the kit. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 5144 5. Remove the driveshaft from the U-Joint Tool and install the snap ring. 6. Repeat Steps 4 and 5 for the opposite side. NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer. 7. Check the universal joint for freedom of movement. 8. Install a new bearing cup. 1. Start a new bearing cup into the driveshaft yoke. 2. Position a new spider in the driveshaft yoke. 3. Install the driveshaft into the U-Joint Tool. 4. Press the bearing cup 6.3 mm (0.25 inch) below the yoke surface. NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing the yellow snap rings, install the black snap rings also supplied in the kit. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 5145 9. Remove the driveshaft from the U-Joint Tool and install the snap ring. 10. Repeat Steps 8 and 9 for the opposite side. 11. Install a new bearing cup. 1. Start a new bearing cup into the driveshaft slip-yoke. 2. Install the driveshaft into the U-Joint Tool. 3. Press the bearing cup 6.3 mm (0.25 inch) below the yoke surface. NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing the yellow snap rings, install the black snap rings also supplied in the kit. 12. Remove the driveshaft from the U-Joint Tool and install the snap ring. 13. Repeat Steps 11 and 12 for the opposite side. NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer to seat the bearing cups. 14. Check the universal joint for freedom of movement. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 5146 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flywheel Bolts 54-64 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5150 Flex Plate: Service and Repair Removal 1. Remove the transmission. 2. Remove the bolts. Installation 1. Position the flywheel and loosely install the bolts. Tighten the bolts in the sequence shown. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the automatic transmission. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission range selector lever in the OD position. ^ Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (OD position). 3. Hang a 1.36 Kg (3 lbs.) weight on the range selector lever. 4. Center the pointer in the middle of the OD position. ^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 1.36 Kg (3 lbs.) weight. 6. Carefully move the shift range selector lever from detent to detent and compare with transmission settings. ^ Re-adjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5164 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5165 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5166 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5167 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5168 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5169 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5170 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5171 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5172 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5173 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5174 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5175 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5176 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5177 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5178 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5179 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5180 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5181 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5182 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5183 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5184 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5185 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5186 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5187 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5188 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5189 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5190 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5191 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5192 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5193 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5194 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5195 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5196 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5197 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5198 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5199 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5200 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5201 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5202 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5203 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5204 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5205 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5206 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5207 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5208 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5209 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5210 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5211 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5212 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5213 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5214 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5215 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5216 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5217 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5218 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5219 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5220 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5221 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5222 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5223 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5224 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5225 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5226 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5227 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5228 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5229 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5230 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5231 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5232 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5233 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5234 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5235 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5236 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5237 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5238 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5239 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5240 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5241 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5242 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5243 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5244 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5245 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5246 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5247 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5248 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5249 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5250 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5251 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5252 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5253 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5254 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5255 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5256 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5257 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5258 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 5269 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 5275 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5279 Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5280 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5284 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5285 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Loosen the digital Transmission Range (TR) bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5286 7. Tighten the bolts. 8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR sensor electrical connector. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5287 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5291 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair Electronic Pressure Control Solenoid: Service and Repair Removal 1. Remove the manual control lever. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 2. Disconnect the molded lead frame from the solenoids. 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC). 3. Disconnect the Electronic Pressure Control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation 1. Install the Electronic Pressure Control (EPC) solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair > Page 5298 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Retaining Screw .................................................................................................................................. .................................................... 9 Nm (80 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 5302 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. 3. Remove the insert plate from the shift lock actuator. ^ Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the automatic transmission. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission range selector lever in the OD position. ^ Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (OD position). 3. Hang a 1.36 Kg (3 lbs.) weight on the range selector lever. 4. Center the pointer in the middle of the OD position. ^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 1.36 Kg (3 lbs.) weight. 6. Carefully move the shift range selector lever from detent to detent and compare with transmission settings. ^ Re-adjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock Inoperative > Page 5324 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 5330 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5334 Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5335 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5339 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5340 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Loosen the digital Transmission Range (TR) bolts. NOTE: Manual shift lever shaft must be in the neutral position. 6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5341 7. Tighten the bolts. 8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR sensor electrical connector. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air suspension.. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5342 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5346 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The anti-lock brake warning indicator illuminates when the anti-lock brake control module detects a fault in the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Page 5352 ABS Light: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Cluster, Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications Anti-Lock Brake Control Module: Specifications Retaining Screws ................................................................................................................................. ................................................................. 1.8-2.8 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 5356 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 5357 Anti-Lock Brake Control Module: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. - Disconnect the control module electrical connector. - Disconnect the pump motor electrical connector. 3. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the module. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Mounting Bolts ..................................................................................................................................... ......................................... 15-17 Nm (11-12 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5361 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5362 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contract with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the battery ground cable. 2. NOTE: Plug each port of the Hydraulic Control Unit (HCU) to prevent brake fluid from spilling. Disconnect the brake lines. 3. Disconnect the anti-lock brake control module electrical connectors. 4. Remove the mounting bracket to HCU bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5363 5. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the module. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. NOTE: Bleed brake system as necessary. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation Traction Control Indicator Lamp: Description and Operation The traction control indicator is located in the indicator lamp module and illuminates when the traction control system is disabled. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Measured using Rotunda EEC-IV 60-Pin Breakout Box Front and Rear 800-1400 ohms Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 5371 Wheel Speed Sensor: Mechanical Specifications Retaining Bolts Front 36-53 in.lb Rear 14-19 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Removal 1. Disconnect the front anti-lock brake sensor electrical connector. 2. Raise and support the vehicle. 3. Remove the routing clips. 4. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the sensor. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5374 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5375 Wheel Speed Sensor: Service and Repair Rear Removal 1. Remove rear seat bottom. 2. Disconnect the rear anti-lock brake sensor electrical connector. 3. Push the sensor harness grommet through the passenger compartment floor. 4. Raise and support the vehicle. 5. Disconnect the routing clips. 6. Remove the rear anti-lock brake sensor. 1 Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5376 2 Remove the sensor. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the Brake Pedal (BP) and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5381 Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of a new part, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the NGS instructions. 2. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 3. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Have an assistant hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5382 6. Tighten the RH rear bleeder screw. 7. Repeat Steps 3, 4, 5 and 6 for the LH rear bleeder screw. 8. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 9. Have an assistant hold firm pressure on the brake pedal. 10. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 11. Tighten the RH front disc brake caliper bleeder screw. 12. Repeat Steps 8, 9, 10 and 11 for the LH front disc brake caliper bleeder screw. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5383 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder has been primed at the bench, install it in the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5384 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2 Loosen the rear-most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5385 Brake Bleeding: Service and Repair Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the 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: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5386 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: This procedure only needs to be performed if the 4-Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been replaced or if the HCU lines have been opened. NOTE: Ford provides no information or procedures to bleed the brake system without the Rotunda New Generation Star (NGS) tester/scan tool. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5387 4. Tighten the RH rear bleeder screw, and disconnect the waste line. 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake Pedal Bracket Nuts .............................................................................................................................................................. 21-29 Nm (16-21 ft. lbs.) Brake Pedal Bracket Bolt ............................................................................. .................................................................................. 18-27 Nm (13-20 ft. lbs.) Pivot Shaft Nut .......... .............................................................................................................................................................. ....... 14-27 Nm (10-20 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5391 Brake Pedal Assy: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the instrument close-out panel pushpins and remove the panel. 3. Remove the stoplight switch retaining pin. 4. Slide the stoplight switch and booster push rod from the brake pedal pin. 5. Remove the brake pedal bracket retaining bolt. 6. Remove the speed control deactivator switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5392 7. Remove the brake pedal bracket retaining nuts. 8. Remove the brake pedal and bracket. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation The brake system warning indicator has a dual function. It illuminates when the parking brake is applied or when a low brake fluid condition exists in the brake master cylinder reservoir. The brake system warning indicator will illuminate when there is a pressure differential between the front and rear brake hydraulic systems. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Front Torque Specifications: Disc Brake Caliper Bolt .......................................................................................................................................................... 28-36 Nm (21-26 lb.ft.) Front Brake Hose Bolt .................................................................................... .................................................................................. 48 Nm (35 lb.ft.) Front Disc Brake Caliper Anchor Plate Bolt .................................................................................................................. 170-230 Nm (125-169 lb.ft.) Disc Brake Caliper Bleeder Screw ......................................................................................................................................... 17-24 Nm (13-17 lb.ft.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front > Page 5401 Brake Caliper: Specifications Rear Torque Specifications: Brake Caliper Bolt ................................................................................................................................ ............................................ 27 Nm (20 lb.ft.) Caliper Flow Bolt .......................................................... .................................................................................................................... 50 Nm (37 lb.ft.) Rear Wheel Disc Brake Adapter Nuts ............................................................................................................................................... 68 Nm (50 lb.ft.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 5402 Brake Caliper: Diagrams Part 1 Of 2 Part 2 Of 2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Brake Caliper: Service and Repair Brake Caliper Bracket Removal 1. Disconnect the rear parking brake cable and conduit. 2. Remove the axle shaft. 3. WARNING: To avoid injury when using air tools, do not hold flag nuts with fingers. Remove the bolts and the rear wheel disc brake adapter. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5405 Brake Caliper: Service and Repair Front Anchor Plate Removal 1. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove and discard the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. Installation 1. CAUTION: Use correct type and length bolts. Follow the removal procedure in reverse order. Install new front disc brake caliper anchor plate bolts. Overhaul Disassembly 1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from disc brake caliper. 3. Apply low air pressure to the fluid port in the disc brake caliper. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper and force out the caliper pistons to the block of wood. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5406 4. Remove the caliper pistons. 1 Remove the block of wood. 2 Remove the caliper pistons. 5. Remove and discard the piston seals and boots. 6. Remove and discard the bleed screw and cap. Assembly 1. CAUTION: Do not hone the caliper bores. Caliper pistons are not available for honed caliper bores. Clean and inspect the caliper pistons and the disc brake caliper. Remove dirt and debris. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5407 - Examine the caliper pistons for surface irregularities, scoring or wear. Replace damaged caliper pistons. - Clean the caliper bores with Metal Parts Brake Cleaner F3AZ-19579-SA or equivalent. Dry thoroughly before re-assembly. - If the caliper bores are corroded or excessively scored, replace the disc brake caliper. - Lubricate the caliper pistons and piston seals before assembly. 2. CAUTION: Never reuse piston seals and dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Lubricate the caliper piston, piston seal and caliper bores with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. 3. Install the caliper piston. 1 Install the piston seal. 2 Install the piston boot on the piston. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4 CAUTION: Be careful not to cock the caliper piston. Press the caliper piston into the bore. 4. Install a new bleed screw and cap. 5. Install the disc brake caliper. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5408 Brake Caliper: Service and Repair Rear Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. 1 Place a block of wood between the caliper bridge and the rear brake disc piston. 2 Apply low air pressure to the fluid port in the rear disc brake caliper. 3 Force the rear brake disc piston out to the block of wood. 4 Remove the block of wood and the rear brake disc piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5409 period of time. 1. Lubricate the following with Ford High Performance DOT 3 Brake Fluid C6AZ-I9542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. cylinder bore - piston seal - rear brake disc piston - dust boot 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear brake disc piston. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5410 5. Install the rear disc brake caliper. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5411 Brake Caliper: Service and Repair Removal and Installation Front Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, Rush eyes with running water for 15 minutes, get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash it with water immediately. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. Plug the front brake hose. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5412 4. Remove the disc brake caliper. 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. 5. Inspect the disc brake caliper. - If leaks or damaged boots are found, disassembly is required. Installation 1. CAUTION: Make sure guide pin boots are properly seated or damage to guide pins can occur. NOTE: Tighten the lower caliper bolt first. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. - Use new copper washers; connect the front brake hose. - Install the front brake hose bolt. 3. Bleed the caliper. 4. NOTE: After the vehicle is on the ground, if equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5413 Ford specification ESA-M6C25-A. If DOT 3 Is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. Install brake master cylinder filler cap. 6. Inspect the brake system operation. Rear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1 Remove bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA- 10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5414 5. Inspect the rear disc brake caliper for leaks. - If leaks are found, disassembly is required. Installation 1. Make sure the stainless steel shoe slippers are correctly positioned. Replace if worn or damaged. 2. Position the anti-rattle clip behind the rear disc brake caliper anchor plate. 3. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5415 4. Install the rear wheel brake hose. - Connect the brake hose and install the caliper flow bolt. Use new copper washers. 5. Bleed the disc brake caliper. 6. NOTE: After the vehicle is on the ground if equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 7. Verify correct brake operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Page 5416 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Pad: Customer Interest Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Pad: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 5430 Brake Pad: Specifications Front Rear Thickness, Min. 0.039 in 0.039 in Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Remove brake master cylinder filler cap. Check brake fluid level in brake master cylinder reservoir. Remove fluid until brake master cylinder reservoir is half full. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. CAUTION: Replace the pad if worn to or past the specified thickness above the metal backing plate or rivets. Replace the pads in complete axle sets. Inspect the pads for wear and contamination. 5. CAUTION: Do not pry in caliper sight hole to retract pistons as this can damage the pistons and boots. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose. Provide a suitable support. Remove the disc brake caliper. 1 Remove two front disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. 6. Remove the disc brake pad anti-rattle clip. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5433 7. Measure the brake disc thickness. - Replace the brake disc if not within specification. 8. Inspect the disc brake caliper. - If leaks or damaged boots are found, disassembly is required. 9. Remove the pads and stainless steel slippers. 1 Remove the pads and verify thickness. 2 Remove the front disc brake caliper anchor plate stainless steel slippers and discard. 10. Inspect the front disc brake anchor plate assembly. - Check the guide pin boots for damage. - Check the guide pins for binding and damage. - Replace worn or damaged pins. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5434 Installation 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads. NOTE: Replace all hardware supplied with pad kit. Install the pads. 1 Install the new front disc brake caliper anchor plate stainless steel slippers. 2 Install the pads. 2. NOTE: Use a wood block or used pad to protect pistons and boots. Compress the caliper pistons. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5435 3. Install the disc brake pad anti-rattle clip. 4. CAUTION: Use care not to damage the bleeder screw or brake disc shield. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 5. Install the wheel and tire assembly. 6. Lower the vehicle. 7. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. Install brake master cylinder filler cap. 8. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Inspect brake operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5436 Brake Pad: Service and Repair Rear Removal 1. Inspect the brake pads for wear or contamination. Install new if worn to or past specification. 2. NOTE: It is not necessary to remove the rear wheel brake hose when performing this procedure. Remove the rear disc brake caliper. 3. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads. Remove the brake pads by pushing inward and rotating the pad up. 4. NOTE: Use a block of wood or used pad to protect the piston and boots. Retract the caliper piston into the rear disc brake caliper. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5437 5. Make sure the slippers are clean and in good condition. Installation 1. CAUTION: Install the brake pads in full axle sets. Do not replace worn brake pads on only one side of vehicle. Install the brake pads. 2. Install the rear disc brake caliper. 3. Verify correct brake operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Front Diameter 12.44 in Thickness Nominal 1.1 in Minimum 1.01 in Minimum brake disc thickess is molded into the brake disc. Variation, Max 0.00035 in Maximum Runout On Vehicle 0.002 in Hub 0.001 in Rear Diameter 11.2 in Thickness Nominal 0.55 in Minimum 0.51 in Minimum brake disc thickess is molded into the brake disc. Variation, Max 0.0004 in Maximum Runout On Vehicle 0.003 in Hub Face 0.001 in Axle Flange 0.005 in Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc Brake Rotor/Disc: Service and Repair Brake Rotor/Disc Front Removal 1. Remove the front disc brake caliper anchor plate. 2. Locate the marked wheel stud and mark the corresponding brake disc lug hole. - This ensures the lowest brake disc runout is maintained during reassembly. 3. Punch out the rivet mandrel prior to drilling rivet head off. 4. CAUTION: To avoid brake disc damage, use care when drilling. Using a 3/8 inch drill bit, drill off rivet heads. 5. CAUTION: If excessive force must be used during brake disc removal, the brake disc Total Indicated Runout (TIR) must be checked at installation. NOTE: If the brake disc cannot be removed easily, apply Rust Penetrant and Inhibitor F2AZ-19A501-A or equivalent meeting Ford specification ESR-M99C56-A on brake disc to wheel hub mating surfaces. Remove the brake disc. Remove remaining rivet body from wheel hub. Installation 1. Clean any rust or debris from brake disc and wheel hub. - Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to clean the brake disc and hub surfaces. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5443 2. Apply High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the hub flange and pilot area. 3. Align the hub and brake disc marks and position the brake disc to the wheel hub. 4. Install brake disc retaining rivets. 5. Install the front disc brake caliper anchor plate. 6. Check Total Indicated Runout (TIR). Rear Removal 1. CAUTION: Never allow the rear disc brake caliper to hang from the brake hose. Provide suitable support. NOTE: When removing the brake disc in this procedure it is not necessary to disconnect the hydraulic lines. Remove the rear disc brake caliper. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5444 2. NOTE: If the brake disc binds on the rear parking brake shoe and linings, remove the adjustment hole access plug and contract the parking brake shoe and lining by rotating the adjuster in the loosening direction. Remove the brake disc. 3. CAUTION: Use a hub-mount brake lathe if necessary to machine the brake disc. Measure the brake disc, and resurface as necessary. Install a new brake disc if beyond specification. Installation 1. Clean any rust or foreign material from the brake disc and wheel hub. 1 Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to clean the brake disc and hub surfaces. 2. Apply High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the hub flange and pilot area. 3. Install the rear brake disc. 4. Install the rear disc brake caliper. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5445 Brake Rotor/Disc: Service and Repair Disc Backing Plate Front Removal 1. Remove the brake disc. 2. Remove the brake disc shield. 1 Drill out three brake disc shield rivets. 2 Remove the brake disc shield. Installation 1. Install the brake disc shield. 1 Position the brake disc shield. 2 Secure with three rivets. 2. Install the brake disc. Rear Removal 1. Remove the rear wheel disc brake adapter. 2. Remove the rear wheel brake disc shield. 1 Drill out the rivets. 2 Remove the rear wheel brake disc shield. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5446 Installation 1. NOTE: Because the rear wheel brake disc shield is held in position by the four rear wheel disc brake adapter bolts, new rivets are not required. Seal the rivet holes with Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A, and install the rear wheel disc brake shield. 2. Install the rear wheel disc brake adapter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Shoe: Customer Interest Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Shoe: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 5466 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 5467 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 5473 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 5474 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the Brake Pedal (BP) and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5480 Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of a new part, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the NGS instructions. 2. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 3. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Have an assistant hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5481 6. Tighten the RH rear bleeder screw. 7. Repeat Steps 3, 4, 5 and 6 for the LH rear bleeder screw. 8. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 9. Have an assistant hold firm pressure on the brake pedal. 10. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 11. Tighten the RH front disc brake caliper bleeder screw. 12. Repeat Steps 8, 9, 10 and 11 for the LH front disc brake caliper bleeder screw. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5482 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder has been primed at the bench, install it in the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5483 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2 Loosen the rear-most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5484 Brake Bleeding: Service and Repair Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the 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: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5485 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: This procedure only needs to be performed if the 4-Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been replaced or if the HCU lines have been opened. NOTE: Ford provides no information or procedures to bleed the brake system without the Rotunda New Generation Star (NGS) tester/scan tool. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5486 4. Tighten the RH rear bleeder screw, and disconnect the waste line. 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Front Torque Specifications: Disc Brake Caliper Bolt .......................................................................................................................................................... 28-36 Nm (21-26 lb.ft.) Front Brake Hose Bolt .................................................................................... .................................................................................. 48 Nm (35 lb.ft.) Front Disc Brake Caliper Anchor Plate Bolt .................................................................................................................. 170-230 Nm (125-169 lb.ft.) Disc Brake Caliper Bleeder Screw ......................................................................................................................................... 17-24 Nm (13-17 lb.ft.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front > Page 5491 Brake Caliper: Specifications Rear Torque Specifications: Brake Caliper Bolt ................................................................................................................................ ............................................ 27 Nm (20 lb.ft.) Caliper Flow Bolt .......................................................... .................................................................................................................... 50 Nm (37 lb.ft.) Rear Wheel Disc Brake Adapter Nuts ............................................................................................................................................... 68 Nm (50 lb.ft.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 5492 Brake Caliper: Diagrams Part 1 Of 2 Part 2 Of 2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Brake Caliper: Service and Repair Brake Caliper Bracket Removal 1. Disconnect the rear parking brake cable and conduit. 2. Remove the axle shaft. 3. WARNING: To avoid injury when using air tools, do not hold flag nuts with fingers. Remove the bolts and the rear wheel disc brake adapter. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5495 Brake Caliper: Service and Repair Front Anchor Plate Removal 1. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove and discard the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. Installation 1. CAUTION: Use correct type and length bolts. Follow the removal procedure in reverse order. Install new front disc brake caliper anchor plate bolts. Overhaul Disassembly 1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from disc brake caliper. 3. Apply low air pressure to the fluid port in the disc brake caliper. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper and force out the caliper pistons to the block of wood. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5496 4. Remove the caliper pistons. 1 Remove the block of wood. 2 Remove the caliper pistons. 5. Remove and discard the piston seals and boots. 6. Remove and discard the bleed screw and cap. Assembly 1. CAUTION: Do not hone the caliper bores. Caliper pistons are not available for honed caliper bores. Clean and inspect the caliper pistons and the disc brake caliper. Remove dirt and debris. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5497 - Examine the caliper pistons for surface irregularities, scoring or wear. Replace damaged caliper pistons. - Clean the caliper bores with Metal Parts Brake Cleaner F3AZ-19579-SA or equivalent. Dry thoroughly before re-assembly. - If the caliper bores are corroded or excessively scored, replace the disc brake caliper. - Lubricate the caliper pistons and piston seals before assembly. 2. CAUTION: Never reuse piston seals and dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Lubricate the caliper piston, piston seal and caliper bores with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. 3. Install the caliper piston. 1 Install the piston seal. 2 Install the piston boot on the piston. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4 CAUTION: Be careful not to cock the caliper piston. Press the caliper piston into the bore. 4. Install a new bleed screw and cap. 5. Install the disc brake caliper. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5498 Brake Caliper: Service and Repair Rear Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. 1 Place a block of wood between the caliper bridge and the rear brake disc piston. 2 Apply low air pressure to the fluid port in the rear disc brake caliper. 3 Force the rear brake disc piston out to the block of wood. 4 Remove the block of wood and the rear brake disc piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5499 period of time. 1. Lubricate the following with Ford High Performance DOT 3 Brake Fluid C6AZ-I9542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. cylinder bore - piston seal - rear brake disc piston - dust boot 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear brake disc piston. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5500 5. Install the rear disc brake caliper. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5501 Brake Caliper: Service and Repair Removal and Installation Front Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, Rush eyes with running water for 15 minutes, get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash it with water immediately. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. Plug the front brake hose. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5502 4. Remove the disc brake caliper. 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. 5. Inspect the disc brake caliper. - If leaks or damaged boots are found, disassembly is required. Installation 1. CAUTION: Make sure guide pin boots are properly seated or damage to guide pins can occur. NOTE: Tighten the lower caliper bolt first. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. - Use new copper washers; connect the front brake hose. - Install the front brake hose bolt. 3. Bleed the caliper. 4. NOTE: After the vehicle is on the ground, if equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5503 Ford specification ESA-M6C25-A. If DOT 3 Is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. Install brake master cylinder filler cap. 6. Inspect the brake system operation. Rear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1 Remove bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA- 10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5504 5. Inspect the rear disc brake caliper for leaks. - If leaks are found, disassembly is required. Installation 1. Make sure the stainless steel shoe slippers are correctly positioned. Replace if worn or damaged. 2. Position the anti-rattle clip behind the rear disc brake caliper anchor plate. 3. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5505 4. Install the rear wheel brake hose. - Connect the brake hose and install the caliper flow bolt. Use new copper washers. 5. Bleed the disc brake caliper. 6. NOTE: After the vehicle is on the ground if equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 7. Verify correct brake operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Page 5506 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Technician Safety Information Brake Fluid: Technician Safety Information SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: ^ Eye Contact - rinse eyes thoroughly with water. ^ Skin Contact - wash skin with soap and water. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Technician Safety Information > Page 5512 Brake Fluid: Vehicle Damage Warnings Use clean, fresh Ford High Performance DOT3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. These types are the only brake fluids that should be used in Ford vehicles. Do not reuse brake fluid drained or bled from the system. - Do not use brake fluid that has been stored in an open container. - Do not mix different types of brake fluid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose Brake Hose/Line: Specifications Brake Hose To Caliper Front .................................................................................................................................................... ................................................. 48 Nm (35 ft. lbs.) Rear ..................................................................... ................................................................................................................................. 50 Nm (37 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose > Page 5517 Brake Hose/Line: Specifications Brake Line Hydraulic Tube Connections .......................................................................................................................................................... 14-20 Nm (10-14 ft. lbs.) Front Master Cylinder Brake Tube ................................................................................................................................................ 22-28 Nm (17-20 ft. lbs.) Rear Master Cylinder Brake Tube ................................................................................................................................................. 15-20 Nm (11-14 ft. lbs.) To ABS Brake Pressure Control Valve Block .......................................................................................................................................... 17 Nm (12 ft. lbs.) NOTE: All hydraulic tubes must be tightened to the specific torque value and be free of fluid leakage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Hose Brake Hose/Line: Description and Operation Brake Hose CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which could result in brake tube failure. Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be properly double flared to provide strong leakproof connections. When bending the tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube. If a section of brake tube is damaged, the entire section must be replaced with a tube of the same type, size, shape and length. When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Hose > Page 5520 Brake Hose/Line: Description and Operation Brake Line CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which could result in brake tube failure. Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be properly double flared to provide strong leakproof connections. When bending the tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube. If a section of brake tube is damaged, the entire section must be replaced with a tube of the same type, size, shape and length. When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications Brake Fluid Control Valve ............................................................................................................................................................. 13-24 Nm (10-17 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 5524 Brake Proportioning/Combination Valve: Description and Operation The brake pressure control valve proportions the pressure to the rear brakes. When the brake pedal is applied, brake fluid pressure passes through the proportioning valves to the rear brake system until the valve split point is reached. - Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear brakes. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Mounting Bolts ..................................................................................................................................... ......................................... 15-17 Nm (11-12 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5528 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5529 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contract with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the battery ground cable. 2. NOTE: Plug each port of the Hydraulic Control Unit (HCU) to prevent brake fluid from spilling. Disconnect the brake lines. 3. Disconnect the anti-lock brake control module electrical connectors. 4. Remove the mounting bracket to HCU bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5530 5. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the module. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. NOTE: Bleed brake system as necessary. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Brake Master Cylinder Nuts ........................................................................................................................................................... 21-29 Nm (16-21 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir Brake Master Cylinder: Description and Operation Brake Fluid Reservoir NOTE: Whenever the brake master cylinder reservoir is removed from the brake master cylinder, new grommets must be installed. The brake master cylinder reservoir: is mounted to the brake master cylinder. - holds fluid supply for each brake master cylinder hydraulic piston. - provides visual fluid level markings. - contains the brake master cylinder fluid level sensor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir > Page 5536 Brake Master Cylinder: Description and Operation Master Cylinder, Brakes The brake master cylinder is a dual piston type. The brake master cylinder operates as follows: When the brake pedal is depressed, pressure is applied by mechanical linkage to the primary and secondary piston. - Brake master cylinder pistons apply hydraulic pressure to the two hydraulic circuits. - ABS brake master cylinder will not be overhauled, due to internal adjustments which require extensive special tools and fixtures. Service is made by replacement only. The brake master cylinder consists of brake master cylinder reservoir - brake master cylinder body Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Master Cylinder: Initial Inspection and Diagnostic Overview Abnormal Conditions Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. Refer to the symptom chart for abnormal condition diagnosis.See: Testing and Inspection/Symptom Related Diagnostic Procedures Normal Conditions The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (i.e., after brake application and release) will remain unchanged. Condition 2: 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. Condition 3: Fluid level will decrease with pad wear. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5539 Brake Master Cylinder: Component Tests and General Diagnostics Bypass Condition Test 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or installed new. Compensator Port Check The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon application or release of the brake pedal is normal and shows that the compensating ports are not plugged. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 5540 Brake Master Cylinder: Adjustments 1. Remove the brake master cylinder. 2. CAUTION: Do not apply the brake pedal with the master cylinder removed from the booster. Adjust the power brake booster-to-brake master cylinder push rod, vacuum applied. 1 Measure the power brake booster-to-brake master cylinder push rod. 2 If necessary, adjust the screw to the correct length. 3. Install the brake master cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the brake master cylinder fluid level switch. 2. Use a suitable suction device to drain the brake master cylinder reservoir. 3. Carefully pry up on the brake master cylinder reservoir and remove. Installation 1. NOTE: Whenever replacing the brake master cylinder reservoir, replace the grommets. Install the brake master cylinder reservoir. 1 Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-I704-DOT 4. Insert the grommets into the brake master cylinder. 2 Press the brake master cylinder reservoir into the grommets until it is fully seated. 3 Connect the brake master cylinder fluid level switch. 4 Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 5543 Brake Master Cylinder: Service and Repair Master Cylinder, Brakes Removal 1. Disconnect the brake tubes. 2. Disconnect the brake master cylinder fluid level switch connector. 3. Remove the brake master cylinder nuts. 4. Remove the wiring harness bracket and position aside. 5. Remove the brake master cylinder. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 5544 1. Follow the removal procedure in reverse order, - Bleed the brake system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Rear Cable and Conduit Retaining Bolts ......................................................................................................................................... 12-15 Nm (9-11 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable: Service and Repair Front Removal 1. Release the parking brake control, using the parking brake release handle. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle on a hoist. 3. Pull the parking brake adjuster clip downward. 4. Apply the parking brake control fully. 5. Push up on the parking brake adjuster clip to lock the adjuster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5551 6. Release the parking brake control, using the parking brake release handle. 7. Disconnect the front parking brake cable and conduit from the LH parking brake rear cable and conduit at the cable connector. 8. Press the retaining tabs, and remove the front parking brake cable and conduit retainer from the frame. 9. Remove the screw retaining the inner front fender apron to the frame. 10. Pullback the front fender apron to expose the front parking brake cable and conduit. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5552 11. Pull the front parking brake cable and conduit through the frame, and let it hang in the wheel housing. 12. Lower the vehicle. 13. Remove the instrument close-out panel pushpins, and remove the panel. 14. Disconnect the front parking brake cable and conduit from the parking brake control. 15. Push the front parking brake cable and conduit down, and remove the front parking brake cable and conduit from inside the wheel housing. Installation 1. Install the front parking brake cable and conduit through the dash panel from inside the wheel housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5553 2. Connect the front parking brake cable and conduit to the parking brake control. 3. Install the instrument close-out panel and the pushpins. 4. Raise the vehicle. 5. Install the front parking brake cable and conduit through the frame. 6. Position the front fender apron, and install the retaining screw. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5554 7. Install the front parking brake cable and conduit retainer to the frame. 8. Connect the front parking brake cable and conduit to the LH parking brake rear cable and conduit at the cable connector. 9. Adjust the cable tension. 10. Turn the air suspension switch on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5555 Parking Brake Cable: Service and Repair Rear Removal 1. Release the parking brake control, using the parking brake release handle. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle on a hoist. 3. Pull the parking brake adjuster clip downward. 4. Lower the vehicle. 5. Apply the parking brake control fully. 6. Raise the vehicle. 7. Push up on the parking brake adjuster clip to lock the adjuster. 8. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5556 9. Release the parking brake control, using the parking brake release handle. 10. Raise the vehicle. 11. Disconnect the front parking brake cable and conduit from the parking brake rear cable and conduit at the cable connector. 12. Press the retaining tabs, and remove the RH parking brake rear cable and conduit from the frame. 13. Disconnect the LH parking brake rear cable and conduit retainer from the cable adjuster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5557 14. Remove the RH parking brake rear cable and conduit retainer bolts. 15. Compress the cable retaining clip, and pull the parking brake rear cable and conduit out of the rear disc brake adapter plate. 16. Disconnect the parking brake rear cable and conduit from the parking brake lever. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5558 17. Unclip the parking brake rear cable and conduit from the axle housing. 18. Remove the parking brake rear cable and conduit. Installation 1. Install the parking brake rear cable and conduit. 2. Connect the parking brake rear cable and conduit to the parking brake lever. 3. Install the parking brake rear cable and conduit in the rear disc brake adapter plate. 4. Clip the RH parking brake rear cable and conduit to the axle housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5559 5. Install the RH parking brake rear cable and conduit retainer bolts. 6. Install the RH parking brake rear cable and conduit to the frame. 7. Connect the LH parking brake rear cable and conduit retainer to the cable adjuster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5560 8. Connect the front parking brake cable and conduit to the parking brake rear cable and conduit at the cable connector. 9. Adjust the cable tension. 10. Turn the air suspension switch on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications Parking Brake Control-to-Body Bolts ............................................................................................................................................ 25-35 Nm (19-25 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5564 Parking Brake Control: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Release the parking brake control, using the parking brake release handle. 3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle on the hoist. 4. Pull the parking brake adjuster clip downward. 5. Apply the parking brake control fully. 6. Push up on the parking brake adjuster clip to lock the adjuster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5565 7. Release the parking brake control, using the parking brake release handle. 8. Disconnect the front parking brake cable and conduit from the cable connector. 9. Lower the vehicle. 10. Unclip the scuff plate and the cowl side trim panel, and remove. 11. Remove the instrument close-out panel pushpins, and remove the panel. 12. Disconnect the parking brake release handle cable from the parking brake control. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5566 13. Remove the retaining screws and the instrument panel steering column cover with the parking brake release handle. 14. Remove the retaining bolts and the instrument panel steering column opening cover reinforcement. 15. In the engine compartment, loosen the Powertrain Control Module (PCM) wiring connector retaining bolt and disconnect the connector. 16. Remove the instrument panel wiring connector retaining bolt, and disconnect the connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5567 17. Remove the shake brace to parking brake control bolt. 18. From under the instrument panel, remove the Powertrain Control Module (PCM). 19. Remove the instrument panel retaining bolts. 20. Pull the instrument panel slightly rearward, and retain it using a small block of wood. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5568 21. Remove the parking brake release vacuum hose from the parking brake release control motor. 22. Disconnect the electrical connector from the parking brake switch. 23. Disconnect the front parking brake cable and conduit from the parking brake control. 24. Remove the parking brake control retaining bolts. 25. Remove the parking brake control. Installation 1. Position the parking brake control. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5569 2. Install the parking brake control retaining bolts. 3. Connect the front parking brake cable and conduit to the parking brake control. 4. Connect the electrical connector to the parking brake switch. 5. Install the parking brake release vacuum hose to the parking brake release control motor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5570 6. Pull the instrument panel slightly rearward, and remove the wood block. 7. Install the instrument panel retaining bolts. 8. Install the shake brace bolt. 9. Install the Powertrain Control Module (PCM). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5571 10. Connect the instrument panel wiring connector, and install the retaining bolt. 11. Connect the Powertrain Control Module (PCM) wiring connector, and install the retaining bolt. 12. Install the instrument panel steering column opening cover reinforcement and the retaining bolts. 13. Install the instrument panel steering column cover, parking brake release handle and retaining screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5572 14. Connect the parking brake release handle cable to the parking brake control. 15. Install the instrument close-out panel, and install the pushpins. 16. Install the cowl side trim panel and scuff plate. 17. Raise the vehicle. 18. Connect the front parking brake cable and conduit to the cable connector. 19. Adjust the parking brake cable tension. 20. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Release Handle Mounting Screw......................................................................................................... .............................................. 1-2 Nm (9-17 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor > Component Information > Specifications Parking Brake Release Motor: Specifications Retaining Screw .................................................................................................................................. .................................................... 3 Nm (26 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the brake disc. 4. Remove the brake shoe adjusting screw spring. 5. Remove the brake shoe adjustment screw. 6. Remove the brake shoe hold down springs. 7. Remove the parking brake shoe and linings. 8. Inspect the components for excessive wear or damage, and install new components as required. Installation 1. Follow the removal procedure in reverse order. - Lubricate the brake shoe contact point before installation of the rear brake shoes, using Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A) (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. - Use a brake adjusting gauge to set the rear brake shoe and lining diameter to 0.5 mm (0.020 inch) less than the inside diameter of the drum portion of the brake disc. - Adjust the parking brake cable tension. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation The power brake booster: is a dual diaphragm, vacuum assisted power brake booster. - reduces brake pedal pressure and travel distance. - is located on the LH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. - is divided into separate chambers by the diaphragm. - Will not operate if vacuum is restricted or if any of the vacuum-related power brake components fail. - is replaced as an assembly. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. The power brake booster check valve: is located on the front of the power brake booster. - is positioned between the power brake booster and the power brake booster vacuum hose. - closes when the engine is turned off. - in the closed position, traps engine vacuum in the power brake booster. - retains vacuum to provide several power assisted brake applications with the engine off. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5586 Vacuum Brake Booster: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the fluid level sensor connector. 3. Position the speed control cable out of the way. 4. Disconnect the power brake booster check valve. 5. Remove the brake master cylinder nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5587 6. Remove the wiring harness bracket, and position aside. 7. Remove the brake master cylinder and position aside. 8. Remove the instrument close-out panel pushpins, and then remove the panel. 9. Remove the stoplight switch retaining pin. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5588 10. Slide the stoplight switch and booster push rod off the brake pedal pin. 11. Remove the brake booster retaining nuts. 12. Remove the power brake booster. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5589 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications Anti-Lock Brake Control Module: Specifications Retaining Screws ................................................................................................................................. ................................................................. 1.8-2.8 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 5594 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 5595 Anti-Lock Brake Control Module: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. - Disconnect the control module electrical connector. - Disconnect the pump motor electrical connector. 3. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the module. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Measured using Rotunda EEC-IV 60-Pin Breakout Box Front and Rear 800-1400 ohms Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 5601 Wheel Speed Sensor: Mechanical Specifications Retaining Bolts Front 36-53 in.lb Rear 14-19 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Removal 1. Disconnect the front anti-lock brake sensor electrical connector. 2. Raise and support the vehicle. 3. Remove the routing clips. 4. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the sensor. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5604 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5605 Wheel Speed Sensor: Service and Repair Rear Removal 1. Remove rear seat bottom. 2. Disconnect the rear anti-lock brake sensor electrical connector. 3. Push the sensor harness grommet through the passenger compartment floor. 4. Raise and support the vehicle. 5. Disconnect the routing clips. 6. Remove the rear anti-lock brake sensor. 1 Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5606 2 Remove the sensor. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5614 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5615 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5616 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5617 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5618 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5619 Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5622 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Service Precautions WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5623 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the steering column lock housing bearing and steering column lock gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing bearing. ^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three o'clock position. Rotate it counterclockwise. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5624 2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install the steering wheel. 4. Install the ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5632 The Starter Relay is located in the High Current Relay Center. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5633 Starter Relay: Description and Operation The starter relay: - is a mini ISO relay. - switches power to the starter solenoid to engage the starter motor when it receives a START signal from the ignition switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5634 Starter Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5635 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5636 Starter Relay: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Press the clips inward and open the relay junction box. 3. Remove the ISO starter relay. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications Battery Cable: Specifications Battery Ground Cable Bolt 7-10 Nm Battery Ground Cable 7-10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 5641 Battery Cable: Description and Operation Vehicles are equipped with a 12 volt maintenance-free battery. WARNING - BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION. - WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. - KEEP BATTERIES OUT OF THE REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized recycling facility for disposal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Generator Output ................................................................................................................................. ................................................................... 130 Amps Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 5647 Alternator: Mechanical Specifications Pulley Ratio Generator Pulley Ratio ........................................................................................................................ .......................................................................... 2.72:1 Torque Specifications Generator Support Bracket Bolts ..................................................................................................................................................... 8-12 Nm (71-106 Lb-In) Generator Mounting Bolts ..................................................................................... ........................................................................... 20-30 Nm (15-22 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 5648 Alternator: Application and ID Generator Type .......................................................................................................................................................... 6-G With Internal Mounted Voltage Regulator Generator ................................................................... ......................................................................................................................................... F6AU-CA Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 5649 Alternator: Description and Operation The generator has an internal voltage regulator that is not serviced separately. The generator and voltage regulator are serviced as an assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 5650 Alternator: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine cover. 1. Remove the screw. 2. Push the cover forward to disengage the front clips, then lift the engine cover straight up. 3. Remove the pushpins and the wiring harness. 4. Remove the four bolts and the generator bracket. 5. Disconnect the electrical connectors. 6. Release the belt tension. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 5651 7. Release the belt from the Generator (GEN). 8. Remove the generator. 1. Loosen the bolts. 2. Pull the generator straight up to remove. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Application and ID Voltage Regulator: Application and ID Voltage Regulator Type ................................................................................................................................................... Electronic Integral With Generator Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5661 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5662 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5663 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5664 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5665 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5666 Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5669 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Service Precautions WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5670 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the steering column lock housing bearing and steering column lock gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing bearing. ^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three o'clock position. Rotate it counterclockwise. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5671 2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install the steering wheel. 4. Install the ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: Customer Interest Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 5683 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: All Technical Service Bulletins Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 5689 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection Starter Drive/Bendix: Testing and Inspection 1. Remove the starter motor. 2. Check the wear patterns on the (A) starter drive and the (B) flywheel ring gear. If the wear pattern is normal, install the starter motor. 3. If the (A) starter drive gear and the flywheel ring gear are not fully meshing or the gears are (B) milled or damaged, replace the starter motor. Replace the flywheel ring gear. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5697 The Starter Relay is located in the High Current Relay Center. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5698 Starter Relay: Description and Operation The starter relay: - is a mini ISO relay. - switches power to the starter solenoid to engage the starter motor when it receives a START signal from the ignition switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5699 Starter Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5700 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5701 Starter Relay: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Press the clips inward and open the relay junction box. 3. Remove the ISO starter relay. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Starter Solenoid Terminal Nuts ............................................................................................................................................................ 5-7 Nm (45-61 Lb-In) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 Circuit Breaker: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5748 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5749 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5750 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5751 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5752 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5753 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5754 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5755 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5761 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5762 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5763 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5764 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5765 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5766 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5767 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5768 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5773 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5791 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5812 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5816 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5821 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5822 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5823 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5824 Multiple Junction Connector: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5825 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5826 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5827 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5828 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5829 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5830 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5831 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5832 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5833 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5834 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5835 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5836 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5837 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5838 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5839 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5840 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5841 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5842 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5843 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5844 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5845 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5846 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5851 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 5855 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 5860 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 5861 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 5866 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 5867 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 Circuit Breaker: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5911 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5912 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5913 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5914 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5915 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5916 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5917 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5918 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5924 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5925 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5926 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5927 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5928 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5929 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5930 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5931 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5936 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5954 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5959 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5960 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5961 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5962 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5963 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5975 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5979 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5984 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5985 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5986 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5987 Multiple Junction Connector: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5988 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5989 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5990 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5991 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5992 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5993 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5994 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5995 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5996 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5997 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5998 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5999 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 6000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 6001 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 6002 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 6003 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 6004 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 6005 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 6006 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 6007 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 6008 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 6009 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6014 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6018 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 6023 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 6024 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 6029 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 6030 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6036 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6037 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6038 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6039 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6040 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6041 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6042 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6043 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6044 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6045 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6046 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6047 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6048 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6049 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6050 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6051 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6052 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6053 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6054 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6055 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6056 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6057 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6058 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6059 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6060 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6061 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6062 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6063 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6064 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6065 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6066 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6067 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6068 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6069 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6070 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6071 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6072 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6073 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6074 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6075 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6076 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6077 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6078 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6079 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6080 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6081 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6082 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6083 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6084 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6085 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6086 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6087 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6088 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6089 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6090 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6091 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6092 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6093 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6094 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6095 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6096 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6097 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6098 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6099 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6101 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6102 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6103 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6104 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6105 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6106 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6107 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6108 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6109 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6110 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6111 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6112 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6113 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6114 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6115 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6116 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6117 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6118 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6119 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6120 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6121 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6122 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6123 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6124 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6125 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6126 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6127 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6128 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6129 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6130 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6131 Alignment: Specifications NOTE: All specifications are given for a vehicle at curb load. CAMBER: Nominal ............................................................................................................................................... ..................................................................... -0.50° Tolerance ............................................................ ..................................................................................................................................................... ±0.75° Difference/Split (Left Minus Right) Nominal ............................................................................................................................................... ................................................................ 0.00° Tolerance .................................................................. ......................................................................................................................................... ±0.75° CASTER: Nominal ............................................................................................................................................... .................................................................... +5.50° Tolerance ............................................................ ..................................................................................................................................................... ±0.75° Difference/Split (Left Minus Right) Nominal ............................................................................................................................................... ................................................................ +0.5° Tolerance .................................................................. ......................................................................................................................................... ±0.75° TOTAL TOE [a] Degree: Nominal ............................................................................................................................................... ............................................................. -0.125° Tolerance .................................................................. ......................................................................................................................................... ±0.25° CLEAR VISION [b]: Nominal ............................................................................................................................................... ....................................................................... -2.0° Tolerance ............................................................ ....................................................................................................................................................... ±3.0° RIDE HEIGHT Base Front .................................................................................................................................................... ........................ 29.6 ±12.7 mm (1.2 ±0.5 inch) Rear ........................................................................... ................................................................................................ 138.0 ±7.60 mm (5.4 ±0.3 inch) Air Suspension Front .................................................................................................................................................... ........................ 27.4 ±12.7 mm (1.1 ±0.5 inch) Rear ........................................................................... .................................................................................................. 132.4 ±7.6 mm (5.2 ±0.3 inch) With Handling package Front .................................................................................................................................................... ........................ 26.0 ±12.7 mm (1.0 ±0.5 inch) Rear ........................................................................... .................................................................................................. 132.4 ±7.6 mm (5.2 ±0.3 inch) Police/NGV Front .................................................................................................................................................... ........................ 26.4 ±12.7 mm (1.0 ±0.5 inch) Rear ........................................................................... .................................................................................................. 132.3 ±7.6 mm (5.2 ±0.3 inch) VEHICLE LEAN (Side to Side Height Difference) Front .................................................................................................................................................... ................................................ 12.7 mm (0.5 inch) Rear ..................................................................... ................................................................................................................................ 12.7 mm (0.5 inch) [a] Positive value is toe-in, negative value is toe-out. [b] Position of steering wheel spoke to horizontal. Negative value specification is counterclockwise. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6132 Alignment: Description and Operation Camber and caster are adjusted by means of two adjustment cams located on each upper control arm. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. 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 Caster is the deviation from vertical of an imaginary line drawn through the ball joints 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. TOE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6133 Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. RIDE HEIGHT Front Ride Height Measurement Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6134 Rear Ride Height Measurement On vehicles equipped with an air suspension system, the vehicle ride height can only be measured accurately after the accurate trim test has been executed using a NGS tester. Wheel Track WHEEL TRACK Refer to image provided. DOGTRACKING Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6135 Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. 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. SHIMMY Shimmy, as observed 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. NIBBLE Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. POOR RETURNABILITY/STICKY STEERING Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. 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 hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road crown). 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° of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20° of turn, most of the turning effort that builds up comes from the mesh of 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 readability problem, it is important to understand the difference between wander and poor groove feel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber 1. Loosen the nuts. 2. To adjust the camber, rotate the adjustment cam. ^ To increase camber, rotate the adjustment cam clockwise. ^ To decrease camber, rotate the adjustment cam counterclockwise. 3. To adjust the caster, rotate the adjustment cam. ^ To increase the caster, rotate the adjustment cam clockwise. ^ To decrease the caster, rotate the adjustment cam counterclockwise. 4. Hold each cam and tighten the nuts. 5. Recheck the camber and caster. Follow the manufacturer's instructions. Readjust the camber and caster as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 6138 Alignment: Service and Repair Toe 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings. Follow the manufacturer's instructions. 4. Loosen the nuts. ^ Clean-and lubricate the steering linkage and tie rod end threads. 5. Rotate the adjusting sleeves to obtain the correct toe setting. 6. Position the adjusting sleeve clamps within the horizontal and vertical limits shown. Tighten the nuts. 7. Recheck the toe settings. Follow the manufacturer's instructions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations Electronic Variable Orifice Steering Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations > Page 6144 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations > Page 6145 Electronic Variable Orifice Steering Module: Service and Repair Removal 1. Lower the panel. 2. Remove the lamp from the panel and disconnect the wiring. 3. Remove the screws. 4. Disconnect the wiring and remove the control module. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6150 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6151 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Retaining Screws ................................................................................................................................. ..................................... 2.3-3.3 Nm (20-29 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6155 Suspension Control Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6156 Suspension Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6157 Suspension Control Module: Description and Operation A microprocessor controls the air suspension system. The microprocessor and its supporting hardware are contained in the air suspension control module. The air suspension control module responds to signals from various sensors in the vehicle to maintain the programmed ride height while the vehicle is either moving or stopped. The air suspension control module accomplishes this by opening and closing solenoid valves to control the amount of air in the air spring(s). The air suspension control module turns on the compressor by applying voltage through the compressor relay to inflate the air spring(s) and raise the vehicle. The air suspension control module opens the vent solenoid to lower the vehicle by releasing air from the air spring(s)in response to signal inputs from the air suspension height sensor(s). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6158 Suspension Control Module: Service and Repair Removal WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Pull out the lower instrument panel insulator. 1 Remove the pushpins. 2 Pull out the lower instrument panel insulator. 4. Remove the lower instrument panel insulator. 1 Disconnect the power point. 2 Disconnect the courtesy lamp. 3 Remove the lower instrument panel insulator. 5. Remove the rear air suspension control module. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the rear air suspension control module. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6159 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Shock Absorber Electronic Steering Sensor Screws ...................................................................................................................... ............................................. 1 Nm (9 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6165 Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module to avoid overcompensation of the air suspension during turns. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6166 Steering Angle Sensor: Service and Repair Removal 1. Remove the screws. 2. Remove the sound panel. 3. Remove the finish panel. 4. Remove the knee bolster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6167 5. Remove the bracket. 6. Remove the sensor. 1 Disconnect the wiring. 2 Remove the screws. 3 Remove the sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications Ride Height Sensor: Specifications Mounting Bracket To Lateral Arm ........................................................................................................................................................... 14 Nm (10 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6172 Ride Height Sensor: Description and Operation The air suspension height sensor sends signals to the air suspension control module. There are three possible conditions that the air suspension control module interprets from the signals of the air suspension height sensors. The conditions are trim height, below trim height, or above trim height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6173 Ride Height Sensor: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Turn the air suspension switch off. 3. Raise and support the vehicle. 4. Disconnect the air suspension height sensor electrical connector. 5. Remove the air suspension height sensor. ^ Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Shock Absorber Electronic Steering Sensor Screws ...................................................................................................................... ............................................. 1 Nm (9 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6177 Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module to avoid overcompensation of the air suspension during turns. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6178 Steering Angle Sensor: Service and Repair Removal 1. Remove the screws. 2. Remove the sound panel. 3. Remove the finish panel. 4. Remove the knee bolster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6179 5. Remove the bracket. 6. Remove the sensor. 1 Disconnect the wiring. 2 Remove the screws. 3 Remove the sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation Suspension Mode Switch: Description and Operation CAUTION: The air suspension switch must be turned to the OFF position when the vehicle is hoisted, jacked, towed, jump started, or raised off the ground, to avoid unnecessary operation of the system and possible damage to the air suspension system components. The air suspension switch provides a signal to the air suspension control module in the ON position to activate the system to maintain the programmed vehicle height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation > Page 6183 Suspension Mode Switch: Service and Repair Removal WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury. 1. Turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Peel back the luggage compartment trim. 1 Remove the pushpins. 2 Peel back the luggage compartment trim. 4. Remove the air suspension switch. 1 From behind the quarter panel reinforcement, depress the clips. 2 Remove the air suspension switch. 5. Disconnect the electrical connector. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair Center Link: Service and Repair Removal 1. Raise and support the vehicle. 2. NOTE: Both the left side and the right side inner tie-rod ends are removed the same way. Only the left side is shown. Remove the nut. 1 Remove the cotter pin. 2 Remove the nut. 3. Using the special tool, remove the tie-rod end from the steering sector shaft arm drag link. 4. Remove the nut. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 6188 5. Using the special tool, disconnect the steering gear sector shaft arm from the steering sector shaft arm drag link. 6. Remove the nut. 1 Remove the cotter pin. 2 Remove the nut and washer. 7. Remove the steering sector shaft arm drag link. Installation NOTE: Before installing the idler arm to the drag link, make sure the idler arm is in the straight ahead position (parallel to the vehicle's centerline). 1. Install the steering sector shaft arm drag link onto the steering idler arm and bracket. 2. Install the washer, nut and a new cotter pin. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 6189 3. Install the steering gear sector shaft arm onto the steering sector shaft arm drag link. Install a new lock nut. 4. NOTE: Both the left side and the right side inner tie-rod ends are installed the same way. Only the left side is shown. Install the tie-rod end, nut and a new cotter pin. 5. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 6190 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Locations Diagnostic Connector: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Locations > Page 6194 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications Idler Arm: Specifications Retaining Bolts .................................................................................................................................... ..................................................... 80 Nm (59 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 6198 Idler Arm: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the nut. 1 Remove the cotter pin. 2 Remove the nut and washer. 3. Remove the steering sector shaft arm drag link. 4. Remove the steering idler arm and bracket. 1 Remove the bolts, washers and nuts. 2 Remove the steering idler arm and bracket. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 6199 1. NOTE: Before installing the idler arm to the drag link, make sure the idler arm is in the straight ahead position (parallel to the vehicle's centerline). Install the steering idler arm and bracket, bolts, washers and nuts. 2. Position the steering sector shaft arm drag link onto the steering idler arm and bracket. 3. Install the washer, nut and a new cotter pin. 4. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Steering - Pitman Arm Inspection Tip Pitman Arm: Technical Service Bulletins Steering - Pitman Arm Inspection Tip Article No. 99-21-9 10/18/99 STEERING - PITMAN ARM INSPECTION - SERVICE TIP FORD: 1998-2000 CROWN VICTORIA LINCOLN: 1998-2000 TOWN CAR MERCURY: 1998-2000 GRAND MARQUIS ISSUE The Workshop Manuals for 1998-2000 Crown Victoria/Grand Marquis and Town Car do not contain a procedure for inspecting the pitman arm ball joint for wear. ACTION The pitman arm ball joint on 1998-2000 Crown Victoria/Grand Marquis and Town Car vehicles can be inspected by referring to the following Inspection Procedure. INSPECTION PROCEDURE 1. Raise vehicle on hoist. 2. Visually inspect the pitman arm ball joint seal. If it is cut or torn, replace the pitman arm (refer to the appropriate Workshop Manual for pitman arm service procedure). 3. Pull down on the centerlink to take any play out of the pitman arm ball joint. Measure the distance from the top of the pitman arm forging to the bottom of the centerlink using digital calipers. Attach a C-clamp between the top of the pitman arm ball joint socket and the pitman arm ball stud. Tighten the C-clamp to fully compress the ball joint and measure from the top of the pitman arm forging to the bottom of the centerlink again. Subtract the second measurement from the first to get the total movement. 4. If more than 2.78 mm (0.110") movement is measured, replace the pitman arm (refer to the appropriate Workshop Manual for service procedure). 5. The nut attaching the pitman arm to the centerlink can be reused. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 304000, 390000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 6204 Pitman Arm: Specifications Retaining Nut To Sector Shaft .................................................................................................................................... .............................................. 305 Nm (225 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 6205 Pitman Arm: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the nuts. 1 Remove the nut. 2 Remove the nut and the lockwasher. 3. Using the special tool, disconnect the steering gear sector shaft arm from the steering sector shaft arm drag link. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 6206 4. Scribe an alignment mark on both the steering gear sector shaft arm and the shaft. 5. Using the special tool, remove the steering gear sector shaft arm. Installation 1. Install the steering gear sector shaft arm. 1 Align the mark on the steering gear sector shaft arm with the alignment mark on the shaft. 2 Install the steering gear sector shaft arm. 3 Install a new lockwasher and nut. Do not tighten the nut. 2. Install the steering gear sector shaft arm onto the steering sector shaft arm drag link. Install the nut and a new lock nut. 3. Lower the vehicle. 4. Check the wheel alignment. Adjust as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 6207 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair NOTE: If the air is not purged from the power steering system correctly, pump failure could result. This condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. A whine heard from the power steering pump may be caused by air in the system. The power steering purging procedure must be performed under the following conditions: ^ Prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. ^ After replacement of any power steering system component (gear, hose, etc.). 1. Remove the power steering fluid reservoir cap. 2. Tightly insert the stopper of vacuum pump into the power steering fluid reservoir. 3. Start the engine and allow it to idle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6212 4. Using the special tool, apply the maximum vacuum for a minimum of three minutes with the engine at idle. Maintain the maximum vacuum with vacuum pump. 5. Release the vacuum source and remove vacuum pump. 6. Add fluid to the center mark of the power steering fluid reservoir. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6213 7. Using the special tool, reinstall vacuum pump stopper and apply maximum vacuum. 8. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes. 9. Stop the engine, release the vacuum source, and remove vacuum pump. 10. Add power steering fluid if necessary. Install the power steering fluid reservoir cap. 11. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Start the engine and cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6214 12. Check for power steering fluid leaks at all connections. If the power steering fluid still shows signs of aeration, repeat this procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 6219 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6220 Power Steering Fluid: Specifications Use Motorcraft MERCON(r) Multi-Purpose ATF, XT-2-QDX or equivalent MERCON(r) approved fluid. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6221 Power Steering Fluid: Service Precautions CAUTION: Use only manufacturer recommended Power Steering Fluid or system damage may result. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair Removal 1. Remove the air cleaner assembly. 2. Remove the bolt and the bracket. Repeat on the opposite side. 3. Disconnect the hoses. 4. Disconnect the hoses. 5. Remove the bolt. Repeat on the opposite side. 6. Push back on the radiator and remove the power steering fluid cooler. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 6225 1. Follow the removal procedure in reverse order. 2. Fill and leak check the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair Removal 1. Drain the reservoir using a hand suction pump. 2. Position a drain pan. 3. Disconnect the power steering reservoir pump hose and the power steering return hose. 4. Remove the screw. 5. Remove the screws and the power steering pump reservoir. Installation 1. Follow the removal procedure in reverse order. 2. Fill and leak check the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Hose To Pump .............................................................................................................................................. ................................................. 40 Nm (30 ft. lbs.) To Gear ................................................................ ................................................................................................................................. 20 Nm (15 ft. lbs.) Return Hose To Gear ............................................................................................................................................... .................................................. 20 Nm (15 ft. lbs.) Routing Clip ......................................................................................................................................... ................................................... 8 Nm (71 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 6232 Power Steering Line/Hose: Service and Repair Removal 1. Refer to the illustration provided for the hose routing and retention points. Installation 1. When connecting a fitting with a seal ring, a new seal ring must be installed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 6233 ^ The special tool is used to install the return line connector seal and the pressure line connector seal. 2. Fill and leak check the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 6234 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Variable Assist Control Valve <--> [Power Steering Pressure Control Valve] > Component Information > Specifications Variable Assist Control Valve: Specifications Power Steering Auxiliary Actuator ........................................................................................................................................................... 17 Nm (13 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Retaining Bolts .................................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 6242 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Flow [1] ................................................................................................................................................ ............................................................. 3.0 ±0.2 gpm Capacity, Min [2] .............................................. ........................................................................................................................................................ 1.4 gpm Relief Pressure ............................................................................................................................ .................................................................... 1200-1380 psi [1] Flow at 50 psi and 2500 rpm pump speed. [2] At 750 psi. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6243 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6244 Power Steering Pump: Application and ID CAUTION: Always use the ID code when ordering service parts. The pump identification code is located on a tag attached to the power steering pump. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump With EVO Steering System Removal 1. Remove the drive belt. 2. Raise the vehicle. 3. Remove the routing bracket. 4. Disconnect the power steering auxiliary actuator electrical connector. 5. Remove the pulley. 6. Disconnect the hose. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6247 7. Disconnect the hose. 8. Remove the four bolts and the power steering pump. 9. If the power steering pump is to be replaced, remove the power steering auxiliary actuator. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6248 1. Follow the removal procedure in reverse order. ^ Install new seal rings as necessary. 2. Fill and leak check the system. Without EVO Steering System Removal 1. Remove the drive belt. 2. Raise the vehicle. 3. Remove the routing bracket. 4. Remove the pulley. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6249 5. Disconnect the hose. 6. Disconnect the hose. 7. Remove the four bolts and the power steering pump. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6250 1. Follow the removal procedure in reverse order. ^ Install new seal rings as necessary. 2. Fill and leak check the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6251 Power Steering Pump: Service and Repair Power Steering Pump Pulley Special Tools Removal 1. Remove the drive belt. 2. Raise the vehicle. 3. CAUTION: Do not apply pressure on the power steering pump rotor shaft. Pressure will damage internal thrust areas of the power steering pump. Use the special tool to remove the pulley. ^ Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, discard the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. Installation 1. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. Use the special tool to install the power steering pump pulley. ^ Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, discard the pulley. If there is no paint or one paint Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6252 mark, use a paint pencil to mark the web area of the pulley near the hub. 2. Lower the vehicle. 3. Install the drive belt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Page 6253 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Service and Repair Power Steering Valve: Service and Repair Removal 1. Raise the vehicle. 2. Remove the engine oil filter. 3. Disconnect the power steering auxiliary actuator electrical connector. 4. Remove the screw and the power steering auxiliary actuator. Installation 1. Follow the removal procedure in reverse order. 2. Fill and check the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations Electronic Variable Orifice Steering Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations > Page 6260 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations > Page 6261 Electronic Variable Orifice Steering Module: Service and Repair Removal 1. Lower the panel. 2. Remove the lamp from the panel and disconnect the wiring. 3. Remove the screws. 4. Disconnect the wiring and remove the control module. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations Electronic Variable Orifice Steering Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations > Page 6266 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations > Page 6267 Electronic Variable Orifice Steering Module: Service and Repair Removal 1. Lower the panel. 2. Remove the lamp from the panel and disconnect the wiring. 3. Remove the screws. 4. Disconnect the wiring and remove the control module. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Shock Absorber Electronic Steering Sensor Screws ...................................................................................................................... ............................................. 1 Nm (9 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6272 Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module to avoid overcompensation of the air suspension during turns. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6273 Steering Angle Sensor: Service and Repair Removal 1. Remove the screws. 2. Remove the sound panel. 3. Remove the finish panel. 4. Remove the knee bolster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6274 5. Remove the bracket. 6. Remove the sensor. 1 Disconnect the wiring. 2 Remove the screws. 3 Remove the sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Shock Absorber Electronic Steering Sensor Screws ...................................................................................................................... ............................................. 1 Nm (9 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Specifications > Page 6278 Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module to avoid overcompensation of the air suspension during turns. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Specifications > Page 6279 Steering Angle Sensor: Service and Repair Removal 1. Remove the screws. 2. Remove the sound panel. 3. Remove the finish panel. 4. Remove the knee bolster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Specifications > Page 6280 5. Remove the bracket. 6. Remove the sensor. 1 Disconnect the wiring. 2 Remove the screws. 3 Remove the sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedures 1. Disconnect the battery ground cable and wait at least one minute. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedures 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Install the passenger air bag module. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 6287 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the vehicle battery connected? Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Warning Switch <--> [Key Reminder Switch] > Component Information > Service and Repair Key Warning Switch: Service and Repair REMOVAL 1. Remove the ignition lock cylinder. 1 Insert the key into the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Release the clip. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure ^ Verify ignition lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications GENERAL Type ..................................................................................................................................................... ............................. Recirculating Ball Torsion Bar Ratio ...................................................................... ...................................................................................................................................................... 14:1 Input Turns (Lock to Lock) ................................................................................................................... ........................................................................ 3.4 Worm Bearing Preload, Max ............................................................................................................................................................. 0.9 Nm (8 inch lbs.) Total Meshload Over Worm Bearing Preload (Over Ends) ............................................................................................................................................... 0.45-1 Nm (4-9 inch lbs.) TIGHTENING SPECIFICATIONS Ball Return Guide Clamp ..................................................................................................................... ............................................... 6 Nm (53 inch lbs.) Fittings at Steering Gear ...................................... .................................................................................................................................. 20 Nm 15 ft. lbs.) Power Steering Auxiliary Actuator ....................................................................................................................................................... 17 Nm (13 ft. lbs.) Retaining Bolts ............................................................................................................ ......................................................................... 78 Nm (58 ft. lbs.) Sector Shaft Cover ....................... ......................................................................................................................................................... 68 Nm (50 ft. lbs.) Valve Housing Bolts .................................................................................................... ......................................................................... 50 Nm (37 ft. lbs.) Steering Gear Race Retaining Nut ....................................................................................................................................... ........................................... 99 Nm (73 ft. lbs.) Race Setscrew ........................................................... .................................................................................................................... 2 Nm (18 inch lbs.) Meshload Adjuster Lock-Nut ............................................................................................................... ................................................ 31 Nm (23 ft. lbs.) Gear Meshload ..................................................... ................................................................................................................. 1.4-1.8 Nm (12-16 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 6294 Steering Gear: Application and ID CAUTION: Always use the ID code when ordering service parts. The steering gear identification code is stamped into the housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Meshload Check Steering Gear: Adjustments Meshload Check MESHLOAD 1. Rotate the input shaft either left or right to the stop. 2. Rotate the input shaft in the opposite direction and count the number of turns. 3. Rotate the input shaft back one-half the number of turns counted. 4. Using an inch-pound torque wrench, measure the torque required to rotate the input shaft 45° either side of center. 5. If the torque exceeds specifications, adjust the meshload. Turn the sector shaft adjusting screw to adjust the meshload. 6. CAUTION: Do not overtighten the lock nut or the threads in the sector shaft housing cover may strip. Tighten the meshload adjuster lock nut. 1 Hold the sector shaft adjusting screw. 2 Tighten the lock nut. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Meshload Check > Page 6297 Steering Gear: Adjustments Meshload Adjustment MESHLOAD ADJUSTMENT 1. NOTE: The engine should not be running. Turn the steering wheel from right stop to left stop at least once. 2. Remove the driver side air bag. 3. Raise and support the vehicle. 4. Remove the steering sector shaft arm drag link nut. 5. Using the special tool, separate the steering sector shaft arm drag link. 6. NOTE: The front wheels should not touch the ground. Lower and support the front of the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Meshload Check > Page 6298 7. NOTE: Reset the steering gear meshload only if the measured rotating torque for total on-center load is less than specification. Attach a torque wrench to the (A) bolt and measure the steering gear meshload from center. 8. Meshload adjustment is necessary if out of specification. 9. Adjust the sector shaft to proper rotating torque. 1 Hold the sector shaft and loosen the meshload adjuster locknut. 2 Adjust the sector shaft. 10. Verify that the rotating torque is to specification. ^ Readjust if necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Meshload Check > Page 6299 11. Tighten the meshload adjuster locknut. 1 Hold the sector shaft. 2 Tighten the locknut. 12. Install the steering sector shaft arm drag link nut. 1 Position the steering sector shaft arm drag link. 2 Install the steering sector shaft arm drag link nut. 13. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 14. Install the driver side air bag. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement Steering Gear: Service and Repair Replacement Removal 1. Separate and remove the cover. 2. Remove and discard the pinch bolt. 3. Make sure the ignition switch is in the locked position. 4. Separate the steering column lower shaft from the steering gear. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6302 5. Disconnect the lines. 6. Raise the vehicle. 7. Remove and discard the lock nut. 8. Using the special tool, separate the steering sector shaft arm drag link from the steering gear sector shaft arm. 9. Remove the bolts and the steering gear. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6303 1. Follow the removal procedure in reverse order. ^ Install a new lock nut and pinch bolt. ^ Install new seal rings as necessary. 2. Fill and leak check the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6304 Steering Gear: Service and Repair Disassembly NOTE: The steering gear input shaft and seals cannot be repaired or replaced separately. Gear replacement may be necessary. 1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise jaws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6305 2. Rotate the power steering gear input shaft and control from stop to stop and then center the gear. 3. Remove the steering gear sector shaft housing cover bolts. 4. Tap on the lower end of the steering gear sector shaft. 5. Remove the steering gear sector shaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6306 6. Remove the locking nut from the steering gear sector shaft adjustment screw. 7. Remove the sector shaft housing cover. ^ Hold the steering gear sector shaft. ^ Turn the housing cover counterclockwise. 8. Remove the valve housing bolts and the identification tag. 9. Remove the valve housing and piston assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6307 10. Remove and discard the seal ring. 11. Remove the ball bearings. 1 Remove the bolts. 2 Remove the steering gear ball return guide clamp. 3 Remove the steering gear ball return guide. 4 Rotate the piston over a container to collect the 27-29 ball bearing. 12. Remove the input shaft valve and housing assembly from the piston. 13. Remove and discard the seal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6308 14. Install the valve housing in the special tool and loosen the setscrew. 15. Using the special tool, remove the race nut. 16. Remove the power steering gear input shaft and control from the valve housing. 17. Rotate the valve housing. 18. Pry the power steering gear input shaft seal out of the valve housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6309 19. Remove the input shaft snap ring. 20. Rotate the valve housing. Using the special tool, remove the bearing and power steering gear input shaft seal. 21. Remove the valve housing from special tool 307-003 (T57L-500-B). 22. Install the steering gear housing in special tool 307-003 (T57L-500-B). Remove the steering gear sector shaft dust seal from the sector shaft seal bore. 23. Remove the spacer. 1 Remove the snap ring. 2 Remove the spacer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6310 24. NOTE: The steering gear sector shaft bearing is not replaceable. Using the special tool, remove the sector shaft seal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6311 Steering Gear: Service and Repair Assembly 1. Lubricate the sector shaft seal bore. ^ Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 2. Using the special tool, install the sector shaft seal. ^ Lubricate the sector shaft seal, using Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 3. Install the spacer. 4. Install the snap ring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6312 5. NOTE: Place the steering gear sector shaft dust seal on the special tool so the raised lip is toward the tool. Using the special tool, install the sector shaft dust seal. ^ Lubricate the steering gear sector shaft dust seal; use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. ^ Fill the space between the steering sector shaft dust seal and the sector shaft seal with Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-Band ESR-M1C159-A. 6. Remove the steering gear housing from the special tool 307-003 (T57L-500-B). 7. Position the input shaft bearing in the valve housing. Using the special tool and a press, seat the input shaft bearing. 8. Using the special tool, and a press, seat the power steering gear input shaft seal. 9. Install the input shaft snap ring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6313 10. Apply a liberal amount of Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-MlC93-B and ESR-M1C159-A to the seal lip and the top surface of the power steering gear input shaft seal. 11. Using the special tool, install the power steering gear input shaft dust seal. ^ The dished or rubber side must face away from the valve housing. 12. Mount the valve housing in the special tool. 13. Install the power steering gear input shaft and control into the valve housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6314 14. Position the power steering gear race nut into the valve housing. 15. Using the special tool, tighten the race nut. 16. Install the setscrew. 17. Remove the valve housing from the special tool 307-003 (T57L-500-B). Position the piston on the worm gear. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6315 18. WARNING: Hold the ball return guides until the cap or clip is reinstalled. Failure to hold the guides will result in a trapped ball or balls, which could cause a vehicle accident. If the ball guides become unseated at any time, remove all the balls and repeat the procedure. Install the steering gear ball return guide on the piston. 19. WARNING: The correct number of balls are required for proper gear operation. Count the balls and insert each carefully. WARNING: To make sure the balls are correctly installed, rotate the steering gear input worm gear and rack from one end of travel to the other without allowing the poppet adjuster to contact the valve housing or moving the valve housing pilot face more than 69.1 mm (2-3/4 inches) from the input end of the rack piston. If the steering gear input worm gear and rack cannot be rotated, reinstall the balls. If a steering gear is installed with a steering gear input worm gear and rack that cannot rotate, the steering gear will not function correctly and steering and gear failure can result. Rotate the piston while holding the steering gear ball return guide and install the 27-29 ball bearings into the opening in the ball guide. 20. Install the steering gear ball return guide clamp. 1 Position the steering gear ball return guide clamp. 2 Install the bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6316 21. Install a new seal ring. 22. Lubricate and install the seal on the piston. ^ Use Multi-Purpose Grease DOAZ-19581AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 23. Install the piston assembly into the steering gear housing. Make sure to align the oil passages in the steering gear housing. 24. Rotate the teeth so they are on the same plane as the steering gear sector shaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6317 25. Loosely install the valve housing bolts and the identification tag, if so equipped. 26. Lubricate the O-ring on the sector shaft housing cover. ^ Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 27. Rotate the housing clockwise and install the sector shaft into the sector shaft housing. 28. Install the sector shaft lock nut. The sector shaft lock nut will be tightened during the steering gear meshload adjustment. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6318 29. Install the sector shaft and housing assembly. Loosely install the sector shaft housing bolts. 30. Tighten the bolts. 31. Tighten the bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 6319 Steering Gear: Tools and Equipment Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications Lower Steering Column Shaft Pinch Bolts Lower ................................................................................................................................................... ........................................... 48 Nm (35 ft. lbs.) Upper ......................................................................... ..................................................................................................................... 30 Nm (22 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 6323 Steering Shaft: Service and Repair Removal 1. CAUTION: The steering column must be in the locked position, or the lower end of the steering column is to be secured or wired in such a way as to prevent the steering column from rotating, resulting in damage to the air bag sliding contact. Remove and discard the pinch bolt. Disconnect the upper half of the lower steering column shaft from the steering column lower yoke. 2. Remove and discard the pinch bolt. Disconnect the lower steering column shafts from each other. 3. Remove the upper half of the lower steering column shaft. 4. Remove the cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 6324 5. Remove and discard the pinch bolt. 6. Disconnect and remove the lower half of the lower steering column shaft from the steering gear. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 6325 1. Follow the removal procedure in reverse order. ^ Install new pinch bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications GENERAL Free Play, Max. ................................................................................................................................... ..................................................... 6 mm (1/4-inch) Turning Effort, Static [1] ....................................... ................................................................................................................................ 2.72 KG (6.0 lbs.) Number of Turns [2] ............................................................................................................................. ......................................................................... 3.4 TIGHTENING SPECIFICATION Retaining Bolt [3] ................................................................................................................................. ................................................. 40 Nm (30 ft. lbs.) [1] Steering wheel turning effort. Engine running. Fluid at operating temperature. [2] Lock to Lock. [3] Use new steering wheel retaining bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6329 Steering Wheel: Service Precautions WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped) . Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6330 Steering Wheel: Service and Repair Service Precautions WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Removal 1. NOTE: Make sure the wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. ^ Disconnect the battery ground cable and wait at least one minute. ^ Disconnect the battery to starter relay cable. 2. Remove the driver side air bag module. 3. Disconnect the sliding contact electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6331 4. Remove and discard the steering wheel bolt. 5. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. Use the special tool to remove the steering wheel. 6. Remove the steering wheel while routing the wires from the air bag sliding contact through the steering wheel. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6332 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Castellated Nuts .................................................................................................................................. ...................................................... 55 Nm (41 ft. lbs.) Adjusting Sleeve ............................................. .......................................................................................................................................... 28 Nm (21 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End: Service and Repair Inner Removal 1. Raise and support the vehicle. 2. NOTE: Both the left side and the right side inner tie-rod ends are removed the same way. Only the left side is shown. Remove the nut. 1 Remove the cotter pin. 2 Remove the nut. 3. Using the special tool, remove the tie-rod end from the steering sector shaft arm drag link. 4. NOTE: Count the number of threads on the old tie-rod end from the end of the shaft to the scribe mark. This is the number of threads that the tie-rod end should be installed into the front wheel spindle tie-rod adjusting sleeve. Remove the inner tie-rod from the front wheel spindle tie-rod adjusting sleeve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 6339 1 Scribe a mark into the threads on the tie-rod end where shown. 2 Loosen the nut and bolt. 3 Remove the tie-rod end. Installation 1. NOTE: Do not tighten the clamp on the front wheel spindle tie-rod adjusting sleeve until the front wheel alignment has been checked. NOTE: Both the left side and the right side inner tie-rod ends are installed the same way. Only the left side is shown. Install the tie-rod end into the front wheel spindle tie-rod adjusting sleeve. 2. Install the tie-rod end, nut and a new cotter pin. 3. Lower the vehicle. 4. Check the wheel alignment. Adjust as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 6340 Tie Rod End: Service and Repair Outer Removal 1. Raise and support the vehicle. 2. NOTE: Both the left side and the right side outer tie-rod ends are removed the same way. Only the left side is shown. Remove the nut. 1 Remove the cotter pin. 2 Remove the nut. 3. Using the special tool, remove the tie-rod end from the front wheel spindle. 4. NOTE: Count the number of threads on the old tie-rod end from the end of the shaft to the scribe mark. This is the number of threads that the tie-rod end should be installed into the front wheel spindle tie-rod adjusting sleeve. Remove the outer tie-rod end from the front wheel spindle tie rod adjusting sleeve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 6341 1 Scribe a mark into the threads on the tie-rod end where shown. 2 Loosen the nut and bolt. 3 Remove the tie-rod end. Installation 1. NOTE: Do not tighten the clamp on the front wheel spindle tie-rod adjusting sleeve until the front wheel alignment has been checked. NOTE: Both the left side and the right side outer tie-rod ends are installed the same way. Only the left side is shown. Install the tie-rod end into the front wheel spindle tie-rod adjusting sleeve. 2. Install the tie-rod end, nut and a new cotter pin. 3. Lower the vehicle. 4. Check the wheel alignment. Adjust as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 6342 Tie Rod End: Service and Repair Replacement Removal 1. Raise and support the vehicle. 2. NOTE: Both the left side and the right side outer tie-rod ends are removed the same way. Only the left side is shown. Remove the nut. 1 Remove the cotter pin. 2 Remove the nut. 3. Using the special tool, remove the tie-rod end from the front wheel spindle. 4. Remove the outer tie-rod from the front wheel spindle tie-rod adjusting sleeve. 1 Scribe a mark into the threads on the tie-rod end where shown. 2 Loosen the nut and bolt. 3 Remove the tie-rod end. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 6343 5. Remove the front wheel spindle tie-rod adjusting sleeve. 1 Scribe a mark into the threads on the front wheel spindle tie-rod adjusting sleeve where shown. 2 Loosen the nut and bolt. 3 Remove the front wheel spindle tie-rod adjusting sleeve. Installation 1. NOTE: Do not tighten the clamp on the front wheel spindle tie-rod adjusting sleeve until the front wheel alignment has been checked. NOTE: Install the front wheel spindle tie-rod adjusting sleeve until the scribe mark on the inner tie-rod end and the front wheel spindle tie-rod adjusting sleeve meet. Install the front wheel spindle tie-rod adjusting sleeve. 2. NOTE: Both the left side and the right side outer tie-rod ends are installed the same way. Only the left side is shown. NOTE: Install the outer tie-rod end into the front wheel spindle tie-rod adjusting sleeve until the scribe mark on the outer tie-rod end and the front wheel spindle tie-rod adjusting sleeve meet. NOTE: Do not tighten the clamp on the front wheel spindle tie-rod adjusting sleeve until the front wheel alignment has been checked. Install the tie-rod end into the front wheel spindle tie-rod adjusting sleeve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 6344 3. Install the tie-rod end, nut and a new cotter pin. 4. Lower the vehicle. 5. Check the wheel alignment. Adjust as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Page 6345 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > NHTSA98V32200 > Jan > 99 > Recall 98V322000: Lower Ball Joint Cracking Ball Joint: Recalls Recall 98V322000: Lower Ball Joint Cracking NHTSA CAMPAIGN ID Number: 98V322000 Component: SUSPENSION: INDEPENDENT FRONT CONTROL ARM: LOWER: BALL JOINT Manufacturer: FORD MOTOR COMPANY Year: 1999 Make: FORD Model: CROWN VICTORIA Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 158191 Summary: Vehicle Description: Certain 1996-1999 Ford Crown Victoria police, fleet, natural gas, and 1996-1999 Lincoln Town Car limousine vehicles that were produced with a lower control arm ball joint containing a one piece bearing; and 1990-1996 Ford Crown Victoria police, fleet, and NGV vehicles and 1990-1996 Lincoln Town Car limousine vehicles that have been serviced with either a ball joint containing the one-piece bearing or a front lower control arm containing ball joint with a one-piece bearing. The one-piece bearing within the lower control arm ball joint can weaken slowly during use and eventually crack. This could result in separation of the ball and cap of the joint, allowing the control arm to drop to the ground. If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk of a crash. Dealers will replace the lower control arm ball joints (2). Owner notification is expected to begin January 18, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contract the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > NHTSA98V322000 > Jan > 99 > Recall 98V322000: Lower Ball Joint Failure Ball Joint: Recalls Recall 98V322000: Lower Ball Joint Failure NHTSA CAMPAIGN ID Number: 98V322000 Component: SUSPENSION: INDEPENDENT FRONT CONTROL ARM: LOWER: BALL JOINT Manufacturer: FORD MOTOR COMPANY Year: 1999 Make: FORD Model: CROWN VICTORIA Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 175000 Summary: Vehicle Description: On certain police, fleet, natural gas, and limousine vehicles, the one-piece bearing within the lower control arm ball joint can weaken slowly during use and eventually crack. This could result in separation of the ball and cap of the joint, allowing the control arm to drop to the ground. If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk of a crash. Dealers will replace the lower control arm ball joints (2). Owner notification is expected to begin January 18, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement Technical Service Bulletin # 98S37 Date: 981201 Recall - Front Lower Control Arm Ball Joint Replacement SAFETY RECALL 98337 Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1990 through 1999 Ford Crown Victoria Police, Fleet, Taxi, Natural Gas Vehicles (NGV), and Lincoln Town Cars Equipped with Limousine Package ^ Original - December, 1998 ^ Important Recall Information ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Attachment III ^ Technical Information ^ Customer Notification Letter - 1995 And Forward Vehicles ^ Customer Notification Letter - 1994 And Prior Vehicles ^ Supplement # 1 - February, 1999 Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1993 through 1999 Ford Crown Victoria Police, Fleet, Natural Gas Vehicles (NGV), Lincoln Town Car Equipped with Limousine Packages - Clarification of Lower Control Arm replacement as it relates to this recall. ^ Dealer Letter ^ Supplement # 2 - April, 1999 Announcing the Availability of Parts for 1994 and Prior Affected Vehicles ^ Dealer Letter ^ Attachment II ^ Labor Allowance ^ Parts Ordering Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6363 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6364 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6365 Attachment I - Administrative Information DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the letter shown. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, provide a copy of the letter as shown and schedule a service appointment. OASIS Use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if: -- an owner cannot be contacted. -- an owner does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. If towing is required, submit per ACES II Manual section 3-8. REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid front suspension lower control arm ball joint replacement made before the date of the Owner Letter (or after the date of the letter if an emergency repair was made away from the servicing dealer), enter using DWE; Program Code - 98S37 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hrs. Attachment II - Labor and Parts Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6366 LABOR ALLOWANCES PARTS REQUIREMENTS DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOESII -- Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. 1995 Model Year and Foward Crown Victoria and Town Car SERVICE PROCEDURE The following service procedure will replace the left side lower ball joint. Repeat the procedure to replace the right side lower ball joint. 1. Open hood. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6367 2. Disconnect front wheel ABS sensor electrical connector. See Figure 1. 3. Route front wheel ABS sensor wiring into wheel well. 4. Raise and support vehicle. 5. Remove left front tire and wheel assembly. 6. Remove caliper anchor bracket retaining bolts. See Figure 2. NOTE: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6368 Do not let caliper assembly hang from brake hose. 7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away from steering knuckle. 8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly. 9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield. 10. Remove brake rotor dust shield. 11. Remove retaining nut, then separate upper part of stabilizer bar link from steering knuckle. 12. Remove cotter pin from tie-rod castle nut. 13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle. 14. Position jack stand under lower control arm. 15. Completely remove lower ball joint stud nut. 16. Reinstall lower ball joint stud nut a maximum of two (2) turns. 17. Remove jack stand supporting lower control arm. 18. Separate ball joint stud from steering knuckle. 19. Position jack stand under lower control arm. 20. Remove lower ball joint stud nut. 21. Using a block of wood for support, position steering knuckle away from lower control arm. See Figure 3. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6369 22. Install Ball Joint Remover D89P-3010-A, Receiving Cup D84P-3395-A4 and U-Joint Tool T74P-4635-C on lower ball joint. See Figure 4. NOTE: Use only hand tools to press ball joint out of lower control arm. 23. Using installed tools and a breaker bar, press ball joint out of lower control arm. 24. Remove tools and ball joint from lower control arm. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6370 25. Install Ball Joint Replacer T8OT-3010-A3, Receiving Cup D84P-3395-A4, U-Joint Tool T74P-4635-C and new ball joint on lower control arm. See Figure 5. NOTE: Use only hand tools to press ball joint into lower control arm. 26. sing installed tools and a breaker bar, press ball joint into lower control arm. 27. Remove tools from lower control arm. 28. Reposition jack stand toward end of control arm. 29. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat steering knuckle on ball joint stud. 30. Install ball joint stud nut. Tighten to 148-201 Nm (110-148 lb-ft). 31. Remove jack stand supporting lower control arm. 32. Install tie-rod end into steering knuckle. Tighten castle nut to 47-63 Nm (35-46 lb-ft). Continue to tighten castle nut until slot for cotter pin is aligned. 33. Install new cotter pin in tie-rod castle nut. 34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 26-35 Nm (20-25 lb-ft). 35. Using rivets, install brake rotor dust shield. 36. Install brake rotor on hub. 37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting bolts to 170-230 Nm (125-169 lb-ft). 38. Route the front wheel ABS sensor wiring into engine compartment. 39. Install left front tire and wheel assembly. 40. Lower vehicle. 41. Connect front wheel ABS sensor electrical connector. 42. Repeat procedure for right side lower ball joint. 43. With engine OFF, pump up brake system. 1994 Model Year and Prior Crown Victoria and Town Car SERVICE PROCEDURE The following service procedure will replace the left side lower ball joint. Repeat the procedure to replace the right side lower ball joint. 1. Open hood. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6371 2. Disconnect front wheel ABS sensor electrical connector, if applicable.See Figure 1. 3. Route front wheel ABS sensor wiring into wheel well, if applicable. 4. Raise and support vehicle. 5. Remove left front tire and wheel assembly. 6. Remove caliper anchor bracket retaining bolts. See Figure 2. NOTE: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6372 Do not let caliper assembly hang from brake hose. 7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away from steering knuckle. 8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly. 9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield. 10. Remove brake rotor dust shield. 11. Remove retaining nut and bolt, then separate upper part of stabilizer bar link from steering knuckle. 12. Remove cotter pin from tie-rod castle nut. 13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle. 14. Position jack stand under lower control arm. 15. Remove cotter pin and loosen castle nut one (1) or two (2) turns. 16. Remove lack stand supporting lower control arm. 17. Separate ball joint stud from steering knuckle. 18. Position jack stand under lower control arm. 19. Remove lower ball joint stud castle nut. 20. Using a block of wood for support, position steering knuckle away from lower control arm. See Figure 3. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6373 21. Install Ball Joint Remover D89P-301 0-A, Receiving Cup D84P-3395-A4 and U-Joint Tool T74P-4635-C on lower ball joint. See Figure 4. NOTE: Use only hand tools to press ball joint out of lower control arm. 22. Using installed tools and a breaker bar, press ball joint out of lower control arm. 23. Remove tools and ball joint from lower control arm. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6374 24. Install Ball Joint Replacer T8OT-301O-A3, Receiving Cup D84P-3395-A4, U-Joint Tool T74P-4635-C and new ball joint on lower control arm. See Figure 5. NOTE: Use only hand tools to press ball joint into lower control arm. 25. Using installed tools and a breaker bar, press ball joint into lower control arm. 26. Remove tools from lower control arm. 27. Reposition jack stand toward end of control arm. 28. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat steering knuckle on ball joint stud. 29. Install ball joint stud castle nut. Tighten castle nut to 108-162 Nm (80-119 lb-ft). Continue to tighten castle nut until slot for cotter pin is aligned. 30. Install new cotter pin in lower ball joint castle nut. 31. Remove jack stand supporting lower control arm. 32. Install tie-rod end into steering knuckle. Tighten castle nut to 47-63 Nm (35-46 lb-ft). Continue to tighten castle nut until slot for cotter pin is aligned. 33. Install new Cotter pin in tie-rod castle nut. 34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 40-55 Nm (30-40 lb4t). 35. Using rivets, install brake rotor dust shield. 36. Install brake rotor on hub. 37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting bolts to 170-230 Nm (125-169 lb-ft). 38. Route the front wheel ABS sensor wiring into engine compartment, if applicable. 39. Install left front tire and wheel assembly. 40. Lower vehicle. 41. Connect front wheel ABS sensor electrical connector, if applicable. 42. Repeat procedure for right side lower ball joint. 43. With engine OFF, pump up brake system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6375 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6376 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6377 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6378 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6379 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6380 Supplement # 2 - Attachment II - Labor and Parts Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6381 LABOR ALLOWANCES DEALER PRICE For latest prices, check or call your: -- Order Processing Center DOESII -- Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > NHTSA98V32200 > Jan > 99 > Recall 98V322000: Lower Ball Joint Cracking Ball Joint: All Technical Service Bulletins Recall 98V322000: Lower Ball Joint Cracking NHTSA CAMPAIGN ID Number: 98V322000 Component: SUSPENSION: INDEPENDENT FRONT CONTROL ARM: LOWER: BALL JOINT Manufacturer: FORD MOTOR COMPANY Year: 1999 Make: FORD Model: CROWN VICTORIA Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 158191 Summary: Vehicle Description: Certain 1996-1999 Ford Crown Victoria police, fleet, natural gas, and 1996-1999 Lincoln Town Car limousine vehicles that were produced with a lower control arm ball joint containing a one piece bearing; and 1990-1996 Ford Crown Victoria police, fleet, and NGV vehicles and 1990-1996 Lincoln Town Car limousine vehicles that have been serviced with either a ball joint containing the one-piece bearing or a front lower control arm containing ball joint with a one-piece bearing. The one-piece bearing within the lower control arm ball joint can weaken slowly during use and eventually crack. This could result in separation of the ball and cap of the joint, allowing the control arm to drop to the ground. If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk of a crash. Dealers will replace the lower control arm ball joints (2). Owner notification is expected to begin January 18, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contract the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > NHTSA98V322000 > Jan > 99 > Recall 98V322000: Lower Ball Joint Failure Ball Joint: All Technical Service Bulletins Recall 98V322000: Lower Ball Joint Failure NHTSA CAMPAIGN ID Number: 98V322000 Component: SUSPENSION: INDEPENDENT FRONT CONTROL ARM: LOWER: BALL JOINT Manufacturer: FORD MOTOR COMPANY Year: 1999 Make: FORD Model: CROWN VICTORIA Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 175000 Summary: Vehicle Description: On certain police, fleet, natural gas, and limousine vehicles, the one-piece bearing within the lower control arm ball joint can weaken slowly during use and eventually crack. This could result in separation of the ball and cap of the joint, allowing the control arm to drop to the ground. If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk of a crash. Dealers will replace the lower control arm ball joints (2). Owner notification is expected to begin January 18, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement Technical Service Bulletin # 98S37 Date: 981201 Recall - Front Lower Control Arm Ball Joint Replacement SAFETY RECALL 98337 Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1990 through 1999 Ford Crown Victoria Police, Fleet, Taxi, Natural Gas Vehicles (NGV), and Lincoln Town Cars Equipped with Limousine Package ^ Original - December, 1998 ^ Important Recall Information ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Attachment III ^ Technical Information ^ Customer Notification Letter - 1995 And Forward Vehicles ^ Customer Notification Letter - 1994 And Prior Vehicles ^ Supplement # 1 - February, 1999 Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1993 through 1999 Ford Crown Victoria Police, Fleet, Natural Gas Vehicles (NGV), Lincoln Town Car Equipped with Limousine Packages - Clarification of Lower Control Arm replacement as it relates to this recall. ^ Dealer Letter ^ Supplement # 2 - April, 1999 Announcing the Availability of Parts for 1994 and Prior Affected Vehicles ^ Dealer Letter ^ Attachment II ^ Labor Allowance ^ Parts Ordering Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6395 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6396 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6397 Attachment I - Administrative Information DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the letter shown. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, provide a copy of the letter as shown and schedule a service appointment. OASIS Use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if: -- an owner cannot be contacted. -- an owner does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. If towing is required, submit per ACES II Manual section 3-8. REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid front suspension lower control arm ball joint replacement made before the date of the Owner Letter (or after the date of the letter if an emergency repair was made away from the servicing dealer), enter using DWE; Program Code - 98S37 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hrs. Attachment II - Labor and Parts Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6398 LABOR ALLOWANCES PARTS REQUIREMENTS DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOESII -- Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. 1995 Model Year and Foward Crown Victoria and Town Car SERVICE PROCEDURE The following service procedure will replace the left side lower ball joint. Repeat the procedure to replace the right side lower ball joint. 1. Open hood. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6399 2. Disconnect front wheel ABS sensor electrical connector. See Figure 1. 3. Route front wheel ABS sensor wiring into wheel well. 4. Raise and support vehicle. 5. Remove left front tire and wheel assembly. 6. Remove caliper anchor bracket retaining bolts. See Figure 2. NOTE: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6400 Do not let caliper assembly hang from brake hose. 7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away from steering knuckle. 8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly. 9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield. 10. Remove brake rotor dust shield. 11. Remove retaining nut, then separate upper part of stabilizer bar link from steering knuckle. 12. Remove cotter pin from tie-rod castle nut. 13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle. 14. Position jack stand under lower control arm. 15. Completely remove lower ball joint stud nut. 16. Reinstall lower ball joint stud nut a maximum of two (2) turns. 17. Remove jack stand supporting lower control arm. 18. Separate ball joint stud from steering knuckle. 19. Position jack stand under lower control arm. 20. Remove lower ball joint stud nut. 21. Using a block of wood for support, position steering knuckle away from lower control arm. See Figure 3. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6401 22. Install Ball Joint Remover D89P-3010-A, Receiving Cup D84P-3395-A4 and U-Joint Tool T74P-4635-C on lower ball joint. See Figure 4. NOTE: Use only hand tools to press ball joint out of lower control arm. 23. Using installed tools and a breaker bar, press ball joint out of lower control arm. 24. Remove tools and ball joint from lower control arm. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6402 25. Install Ball Joint Replacer T8OT-3010-A3, Receiving Cup D84P-3395-A4, U-Joint Tool T74P-4635-C and new ball joint on lower control arm. See Figure 5. NOTE: Use only hand tools to press ball joint into lower control arm. 26. sing installed tools and a breaker bar, press ball joint into lower control arm. 27. Remove tools from lower control arm. 28. Reposition jack stand toward end of control arm. 29. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat steering knuckle on ball joint stud. 30. Install ball joint stud nut. Tighten to 148-201 Nm (110-148 lb-ft). 31. Remove jack stand supporting lower control arm. 32. Install tie-rod end into steering knuckle. Tighten castle nut to 47-63 Nm (35-46 lb-ft). Continue to tighten castle nut until slot for cotter pin is aligned. 33. Install new cotter pin in tie-rod castle nut. 34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 26-35 Nm (20-25 lb-ft). 35. Using rivets, install brake rotor dust shield. 36. Install brake rotor on hub. 37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting bolts to 170-230 Nm (125-169 lb-ft). 38. Route the front wheel ABS sensor wiring into engine compartment. 39. Install left front tire and wheel assembly. 40. Lower vehicle. 41. Connect front wheel ABS sensor electrical connector. 42. Repeat procedure for right side lower ball joint. 43. With engine OFF, pump up brake system. 1994 Model Year and Prior Crown Victoria and Town Car SERVICE PROCEDURE The following service procedure will replace the left side lower ball joint. Repeat the procedure to replace the right side lower ball joint. 1. Open hood. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6403 2. Disconnect front wheel ABS sensor electrical connector, if applicable.See Figure 1. 3. Route front wheel ABS sensor wiring into wheel well, if applicable. 4. Raise and support vehicle. 5. Remove left front tire and wheel assembly. 6. Remove caliper anchor bracket retaining bolts. See Figure 2. NOTE: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6404 Do not let caliper assembly hang from brake hose. 7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away from steering knuckle. 8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly. 9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield. 10. Remove brake rotor dust shield. 11. Remove retaining nut and bolt, then separate upper part of stabilizer bar link from steering knuckle. 12. Remove cotter pin from tie-rod castle nut. 13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle. 14. Position jack stand under lower control arm. 15. Remove cotter pin and loosen castle nut one (1) or two (2) turns. 16. Remove lack stand supporting lower control arm. 17. Separate ball joint stud from steering knuckle. 18. Position jack stand under lower control arm. 19. Remove lower ball joint stud castle nut. 20. Using a block of wood for support, position steering knuckle away from lower control arm. See Figure 3. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6405 21. Install Ball Joint Remover D89P-301 0-A, Receiving Cup D84P-3395-A4 and U-Joint Tool T74P-4635-C on lower ball joint. See Figure 4. NOTE: Use only hand tools to press ball joint out of lower control arm. 22. Using installed tools and a breaker bar, press ball joint out of lower control arm. 23. Remove tools and ball joint from lower control arm. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6406 24. Install Ball Joint Replacer T8OT-301O-A3, Receiving Cup D84P-3395-A4, U-Joint Tool T74P-4635-C and new ball joint on lower control arm. See Figure 5. NOTE: Use only hand tools to press ball joint into lower control arm. 25. Using installed tools and a breaker bar, press ball joint into lower control arm. 26. Remove tools from lower control arm. 27. Reposition jack stand toward end of control arm. 28. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat steering knuckle on ball joint stud. 29. Install ball joint stud castle nut. Tighten castle nut to 108-162 Nm (80-119 lb-ft). Continue to tighten castle nut until slot for cotter pin is aligned. 30. Install new cotter pin in lower ball joint castle nut. 31. Remove jack stand supporting lower control arm. 32. Install tie-rod end into steering knuckle. Tighten castle nut to 47-63 Nm (35-46 lb-ft). Continue to tighten castle nut until slot for cotter pin is aligned. 33. Install new Cotter pin in tie-rod castle nut. 34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 40-55 Nm (30-40 lb4t). 35. Using rivets, install brake rotor dust shield. 36. Install brake rotor on hub. 37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting bolts to 170-230 Nm (125-169 lb-ft). 38. Route the front wheel ABS sensor wiring into engine compartment, if applicable. 39. Install left front tire and wheel assembly. 40. Lower vehicle. 41. Connect front wheel ABS sensor electrical connector, if applicable. 42. Repeat procedure for right side lower ball joint. 43. With engine OFF, pump up brake system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6407 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6408 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6409 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6410 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6411 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6412 Supplement # 2 - Attachment II - Labor and Parts Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6413 LABOR ALLOWANCES DEALER PRICE For latest prices, check or call your: -- Order Processing Center DOESII -- Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.012 in (0-0.3mm) Reference Diagram ...................................................... B - but a jackstand must be placed under the lower control arm to "load the suspension". Front Upper Balljoint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 6416 Reference Diagram ...................................................... C - but a jackstand must be placed under the lower control arm to "load the suspension". Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 6417 Ball Joint: Specifications Ball Joint, Lower GENERAL Lateral Backlash, Max. ........................................................................................................................ .......................................... 1.0 mm (0.03937 inch) End Play, Max. .................................................... .............................................................................................................................. 0.5 mm (0.020 inch) TIGHTENING SPECIFICATIONS Retaining Bolts To Spindle ........................................................................................................................................... ....................................... 175 Nm (129 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 6418 Ball Joint: Specifications Ball Joint, Upper GENERAL Lateral Backlash, Max. ........................................................................................................................ .............................................. 0.4 mm (0.015 inch) End Play, Max. .................................................... .............................................................................................................................. 0.5 mm (0.020 inch) TIGHTENING SPECIFICATIONS Retaining Bolts To Upper Arm ...................................................................................................................................... ...................................... 175 Nm (129 ft. lbs.) To Spindle ................................................................... ................................................................................................................... 90 Nm (66 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection Ball Joint: Testing and Inspection Ball Joint Inspection BALL JOINT INSPECTION-BACKLASH 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Inspect the ball joint boots for tears. If torn, install new ball joints as necessary. 3. Prior to inspecting the ball joints for lateral backlash and end play, inspect the wheel bearings. 4. Using a safety stand, support the front suspension lower arm to be inspected. 5. NOTE: Wheel and tire assembly removed for clarity. While an assistant pushes and pulls equally on the top and bottom of the tire, observe any relative lateral backlash between the front suspension upper arm and the front wheel spindle. If the lateral backlash is at or exceeds the specification, a new ball joint must be installed. 6. NOTE: Wheel and tire assembly removed for clarity. While an assistant moves the tire up and down, observe any relative end play between the front suspension upper arm and the front wheel spindle. If the end play is at or exceeds the specification, a new ball joint must be installed. 7. Remove the wheel and tire assembly. 8. Separate the front suspension lower arm from the front wheel spindle. ^ Discard any fasteners that are removed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 6421 9. Using the special tool, move the ball joint as shown and check for any lateral backlash. If the lateral backlash is at, or exceeds, the specification, a new ball joint must be installed. 10. Using the special tool, move the ball joint as shown and check for any end play. If the end play is at, or exceeds, the specification, a new ball joint must be installed. 11. Connect the front suspension lower arm to the front wheel spindle. ^ Install new fasteners. 12. Install the wheel and tire assembly. 13. Remove the safety stand. 14. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 6422 Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.012 in (0-0.3mm) Reference Diagram ...................................................... B - but a jackstand must be placed under the lower control arm to "load the suspension". Front Upper Balljoint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 6423 Reference Diagram ...................................................... C - but a jackstand must be placed under the lower control arm to "load the suspension". Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower Ball Joint: Service and Repair Ball Joint, Lower Removal 1. Remove the front wheel spindle. 2. Remove and discard the ball joint dust boot. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 6426 3. Using the special tools, press the ball joint from the suspension lower arm. Installation 1. NOTE: When installing a new front suspension lower ball joint, the protective cover must be left in place during installation to protect the ball joint seal. It may be necessary to cut off the end of the cover to allow it to pass through the receiving cup. Using the special tools, install the lower ball joint. 2. Discard the protective cover and check the front suspension lower ball joint to make sure it is fully seated in the front suspension lower arm and the ball joint seal is free of cuts or tears. 3. Install the spindle. 4. Check wheel alignment. Adjust as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 6427 Ball Joint: Service and Repair Ball Joint, Upper Removal 1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Support the suspension lower arm with a jack stand. 4. Remove the nut and pinch bolt. Discard the nut. 5. Mark the position of the alignment cams relative to the suspension upper arm for assembly reference. 6. Remove the nuts, the alignment cams and the ball joint. Discard the nuts. Installation NOTE: Align the reference marks made during removal when installing the alignment cams. NOTE: The nuts retaining the ball joint to the upper arm and the spindle are of a torque prevailing design. New nuts must be installed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 6428 1. To install, reverse the removal procedure. 2. Check wheel alignment. Adjust as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Page 6429 Ball Joint: Tools and Equipment Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement Technical Service Bulletin # 00B60 Date: 010201 Campaign - Rear Upper Control Arm Reinforcement 00B60 Owner Notification Program All 1998 through 2000 Model Year Crown Victoria Police Interceptor, Taxi Cab, Natural Gas Vehicles (NGV), and Lincoln Town Car Limousine Prep Package Vehicles - Rear Upper Control Arm Bracket Reinforcement. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Owner Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6438 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6439 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles brought to your dealership. DEALER-OWNER CONTACT Promptly correct all affected vehicles on the enclosed list and other eligible vehicles brought to your dealership. Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Rental vehicle coverage is not included under this program. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6440 Attachment II - Parts and Labor Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted. DOR/COR NUMBER DOR/COR Number 50213 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SEVERE DUTY REAR FRAME REPAIR AFFECTED VEHICLES: 1998 AND 2000 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR (LIMOUSINE) OVERVIEW This procedure is for repairing cracks and installing reinforcement brackets on the rear control arm mounts. Depending on the size of the cracks, some or all of the mounts will require coach welds. All of the control arm mounts will have reinforcement brackets installed on them. INSPECTION NOTE: All illustrations show the right side, the left side is similar. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6441 1. Record radio stations. 2. Disconnect the battery ground cable. NOTE: Upon reassembly, the control arms must be tightened with the vehicle suspension at ride height. Therefore, the shock absorbers must be marked while the vehicle is still on the ground to show ride height before the control arms are removed. 3. While parked on a level surface, mark the rear suspension shock absorbers relative to the position of their protective sleeves. 4. Raise the vehicle on a hoist and remove the rear wheels. NOTE: Inspect both sides of the vehicle. 5. Clean and inspect the areas of the upper and lower control arm mounts for cracks as indicated in the illustration. Measure the length of any cracks that are located. See Figure 1. A. If any of the control arm mounts have separated from the frame rail, do not continue with this procedure. Contact the recall hotline at 1-800-325-5621 for further instruction. B. If no cracks are located, install reinforcement brackets on ALL control arm mounts. Perform REINFORCEMENT BRACKET INSTALLATION. C. Vehicles with only cracks of less than one-half inch in length, proceed as follows. ^ Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and strategically placing coach welds on ONLY the control arm mount(s), which contain cracks. ^ Perform REINFORCEMENT BRACKET INSTALLATION, installing reinforcement brackets on ALL control arm mounts. D. Vehicles with any cracks 1/2 inch long or greater, proceed as follows. ^ Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and placing coach welds on ALL the control arm mounts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6442 ^ Perform REINFORCEMENT BRACKET INSTALLATION, installing reinforcement brackets on ALL control arm mounts. CRACK REPAIR AND COACH WELD PLACEMENT NOTE: Removal of control arm(s) (steps 3 or 4) is not necessary for mounts that do not require coach welds. 1. Position safety stands under the rear axle housing. 2. If equipped with an air spring, wrap the air spring in a protective welding blanket. 3. Loosen the rear pivot bolt on the lower control arm, then remove the front pivot bolt. Rotate the lower control arm downward, away from the frame mount. 4. Remove the upper control arm pivot bolts, then remove the upper control arm. CAUTION Grind only enough metal away to form the V-groove. Do not grind completely through the frame rail or mount parent metal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6443 5. Grind a V-groove in all cracks, then remove the E-coat from around the cracks. Mig weld the groove, using standard mig welding procedures. See Figures 2 and 3. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6444 6. Remove the E-coat from the frame rail(s) and control arm mounts(s) at the coach weld positions as indicated in the illustrations. See Figures 4 and 5. 7. Place one (1) inch coach welds onto the frame rail(s)/control arm mount(s) (starting at the edge of the mount) as indicated in the illustrations. See Figures 4 and 5. REINFORCEMENT BRACKET INSTALLATION NOTE: If equipped with an air spring, wrap the air spring in a protective welding blanket (if not previously installed during crack repair). NOTE: Reinforcement brackets MAY be welded onto mounts without removal of control arms. CAUTION Burn-through is not permitted. If any burn-through occurs, the hole must be filled. CAUTION Do not weld on the bends of the brackets. CAUTION Only remove E-coat and any weld material that interferes with reinforcement bracket fit. Do not grind frame parent metal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6445 1. Prep the frame rail/upper control arm mount by removing the E-coat in the reinforcement bracket mounting area. If necessary grind the weld on the front edge of the upper control arm mount. Grind this weld only if it interferes with the reinforcement bracket sitting flush to the frame rail (bracket must not rock). See Figure 6. 2. Position the upper control arm mount reinforcement bracket with the slotted hole closest to the frame rail. The bracket must fit flush to the frame rail and must be centered vertically and flush with the outer face of the upper control arm mount. Clamp the bracket into place. See Figure 6. 3. Tack weld the upper control arm mount reinforcement bracket into place. Remove the clamp(s). Then finish weld the bracket following the sequence and direction as indicated in the illustration. See Figure 7. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6446 4. Prep the frame rail/lower control arm mount by removing the E-coat in the reinforcement bracket mounting area. See Figure 8. 5. Position the lower control arm mount reinforcement bracket. The bracket must fit flush to the frame rail and flush with the outer face of the lower control arm mount. To begin, clamp the bracket to the frame rail only. See Figure 8. 6. Tack weld the lower control arm mount reinforcement bracket to the frame rail. Then clamp and tack weld the bracket to the lower control arm mount. Remove the clamp(s). Then finish weld the bracket following the sequence and direction as indicated in the illustration. See Figure 9. FINAL ASSEMBLY 1. Remove weld blankets, if previously installed. 2. Install all of the control arms and/or flag nut(s) that were removed. Do not final tighten at this time. 3. Remove the safety stands. WARNING RIDE HEIGHT MUST BE ACHIEVED BY SUPPORTING THE REAR AXLE WITH SHORT SAFETY STANDS WITH THE FRONT WHEELS ON THE FLOOR. ATTEMPTING TO POSITION THE REAR AXLE TO RIDE HEIGHT WHILE THE VEHICLE IS STILL SUPPORTED BY THE HOIST MAY RESULT IN SUDDEN SHIFTING OF THE VEHICLE ON THE HOIST AND PERSONAL INJURY. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6447 4. Position two (2) short safety stands directly under the rear axle housing. Lower the hoist so the rear axle is supported by the jack stands and the front wheels fully contact the floor. 5. Verify the rear shock absorber ride height reference marks are in alignment. NOTE: Tighten all of the control arms that were removed. 6. Tighten both lower control arm pivot bolts and the upper control arm to frame mount pivot bolt to 150 Nm (111 lb-ft). Tighten the upper control arm to axle bracket pivot bolt to 103 Nm (76 lb-ft). 7. Raise the vehicle on a hoist, then remove the safety stands. 8. Spray undercoating on reinforcement brackets, welds and all bare metal (avoid excessive overspray). 9. Install the rear wheels. Tighten the lug nuts to 129 Nm (95 lb-ft). 10. Lower the vehicle, then connect the battery ground cable. 11. Program the radio stations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6448 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6449 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement Technical Service Bulletin # 00B60 Date: 010201 Campaign - Rear Upper Control Arm Reinforcement 00B60 Owner Notification Program All 1998 through 2000 Model Year Crown Victoria Police Interceptor, Taxi Cab, Natural Gas Vehicles (NGV), and Lincoln Town Car Limousine Prep Package Vehicles - Rear Upper Control Arm Bracket Reinforcement. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Owner Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6455 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6456 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles brought to your dealership. DEALER-OWNER CONTACT Promptly correct all affected vehicles on the enclosed list and other eligible vehicles brought to your dealership. Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Rental vehicle coverage is not included under this program. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6457 Attachment II - Parts and Labor Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted. DOR/COR NUMBER DOR/COR Number 50213 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SEVERE DUTY REAR FRAME REPAIR AFFECTED VEHICLES: 1998 AND 2000 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR (LIMOUSINE) OVERVIEW This procedure is for repairing cracks and installing reinforcement brackets on the rear control arm mounts. Depending on the size of the cracks, some or all of the mounts will require coach welds. All of the control arm mounts will have reinforcement brackets installed on them. INSPECTION NOTE: All illustrations show the right side, the left side is similar. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6458 1. Record radio stations. 2. Disconnect the battery ground cable. NOTE: Upon reassembly, the control arms must be tightened with the vehicle suspension at ride height. Therefore, the shock absorbers must be marked while the vehicle is still on the ground to show ride height before the control arms are removed. 3. While parked on a level surface, mark the rear suspension shock absorbers relative to the position of their protective sleeves. 4. Raise the vehicle on a hoist and remove the rear wheels. NOTE: Inspect both sides of the vehicle. 5. Clean and inspect the areas of the upper and lower control arm mounts for cracks as indicated in the illustration. Measure the length of any cracks that are located. See Figure 1. A. If any of the control arm mounts have separated from the frame rail, do not continue with this procedure. Contact the recall hotline at 1-800-325-5621 for further instruction. B. If no cracks are located, install reinforcement brackets on ALL control arm mounts. Perform REINFORCEMENT BRACKET INSTALLATION. C. Vehicles with only cracks of less than one-half inch in length, proceed as follows. ^ Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and strategically placing coach welds on ONLY the control arm mount(s), which contain cracks. ^ Perform REINFORCEMENT BRACKET INSTALLATION, installing reinforcement brackets on ALL control arm mounts. D. Vehicles with any cracks 1/2 inch long or greater, proceed as follows. ^ Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and placing coach welds on ALL the control arm mounts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6459 ^ Perform REINFORCEMENT BRACKET INSTALLATION, installing reinforcement brackets on ALL control arm mounts. CRACK REPAIR AND COACH WELD PLACEMENT NOTE: Removal of control arm(s) (steps 3 or 4) is not necessary for mounts that do not require coach welds. 1. Position safety stands under the rear axle housing. 2. If equipped with an air spring, wrap the air spring in a protective welding blanket. 3. Loosen the rear pivot bolt on the lower control arm, then remove the front pivot bolt. Rotate the lower control arm downward, away from the frame mount. 4. Remove the upper control arm pivot bolts, then remove the upper control arm. CAUTION Grind only enough metal away to form the V-groove. Do not grind completely through the frame rail or mount parent metal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6460 5. Grind a V-groove in all cracks, then remove the E-coat from around the cracks. Mig weld the groove, using standard mig welding procedures. See Figures 2 and 3. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6461 6. Remove the E-coat from the frame rail(s) and control arm mounts(s) at the coach weld positions as indicated in the illustrations. See Figures 4 and 5. 7. Place one (1) inch coach welds onto the frame rail(s)/control arm mount(s) (starting at the edge of the mount) as indicated in the illustrations. See Figures 4 and 5. REINFORCEMENT BRACKET INSTALLATION NOTE: If equipped with an air spring, wrap the air spring in a protective welding blanket (if not previously installed during crack repair). NOTE: Reinforcement brackets MAY be welded onto mounts without removal of control arms. CAUTION Burn-through is not permitted. If any burn-through occurs, the hole must be filled. CAUTION Do not weld on the bends of the brackets. CAUTION Only remove E-coat and any weld material that interferes with reinforcement bracket fit. Do not grind frame parent metal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6462 1. Prep the frame rail/upper control arm mount by removing the E-coat in the reinforcement bracket mounting area. If necessary grind the weld on the front edge of the upper control arm mount. Grind this weld only if it interferes with the reinforcement bracket sitting flush to the frame rail (bracket must not rock). See Figure 6. 2. Position the upper control arm mount reinforcement bracket with the slotted hole closest to the frame rail. The bracket must fit flush to the frame rail and must be centered vertically and flush with the outer face of the upper control arm mount. Clamp the bracket into place. See Figure 6. 3. Tack weld the upper control arm mount reinforcement bracket into place. Remove the clamp(s). Then finish weld the bracket following the sequence and direction as indicated in the illustration. See Figure 7. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6463 4. Prep the frame rail/lower control arm mount by removing the E-coat in the reinforcement bracket mounting area. See Figure 8. 5. Position the lower control arm mount reinforcement bracket. The bracket must fit flush to the frame rail and flush with the outer face of the lower control arm mount. To begin, clamp the bracket to the frame rail only. See Figure 8. 6. Tack weld the lower control arm mount reinforcement bracket to the frame rail. Then clamp and tack weld the bracket to the lower control arm mount. Remove the clamp(s). Then finish weld the bracket following the sequence and direction as indicated in the illustration. See Figure 9. FINAL ASSEMBLY 1. Remove weld blankets, if previously installed. 2. Install all of the control arms and/or flag nut(s) that were removed. Do not final tighten at this time. 3. Remove the safety stands. WARNING RIDE HEIGHT MUST BE ACHIEVED BY SUPPORTING THE REAR AXLE WITH SHORT SAFETY STANDS WITH THE FRONT WHEELS ON THE FLOOR. ATTEMPTING TO POSITION THE REAR AXLE TO RIDE HEIGHT WHILE THE VEHICLE IS STILL SUPPORTED BY THE HOIST MAY RESULT IN SUDDEN SHIFTING OF THE VEHICLE ON THE HOIST AND PERSONAL INJURY. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6464 4. Position two (2) short safety stands directly under the rear axle housing. Lower the hoist so the rear axle is supported by the jack stands and the front wheels fully contact the floor. 5. Verify the rear shock absorber ride height reference marks are in alignment. NOTE: Tighten all of the control arms that were removed. 6. Tighten both lower control arm pivot bolts and the upper control arm to frame mount pivot bolt to 150 Nm (111 lb-ft). Tighten the upper control arm to axle bracket pivot bolt to 103 Nm (76 lb-ft). 7. Raise the vehicle on a hoist, then remove the safety stands. 8. Spray undercoating on reinforcement brackets, welds and all bare metal (avoid excessive overspray). 9. Install the rear wheels. Tighten the lug nuts to 129 Nm (95 lb-ft). 10. Lower the vehicle, then connect the battery ground cable. 11. Program the radio stations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6465 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6466 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Page 6467 Control Arm: Specifications RETAINING BOLTS/NUTS Front Upper Arm to Frame............................................................................................................................. ....................................... 175 Nm (129 ft. lbs.) Lower Arm to Frame .................................................. ................................................................................................................ 175 Nm (129 ft. lbs.) Rear Lower Arm Front and Rear .................................................................................................................................... .................................. 150 Nm (111 ft. lbs.) Upper Arm Front (Frame) ...................................................................................................................................... .................................. 150 Nm (111 ft. lbs.) Rear (Axle) ...................................................................... ....................................................................................................... 103 Nm (76 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Control Arm: Service and Repair Front Lower Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality of substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the cotter pin and nut. Discard the cotter pin. 4. Using the special tool, remove the tie-rod end from the front wheel spindle. 5. Remove the coil spring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6470 6. NOTE: The lower control arm ball joint nut is coated with a dry adhesive and a new nut must be installed whenever the nut is loosened or removed. Remove and discard the nut. 7. Using the special tool, remove the front suspension lower arm. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6471 1. NOTE: The lower control arm ball joint nut is coated with a dry adhesive and a new nut must be installed whenever the nut is loosened or removed. NOTE: Do not tighten the front suspension lower arm bolts until the vehicle's suspension is at curb height. To install, reverse the removal procedure. Upper Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Place a suitable jack stand under the front suspension lower arm and lower the vehicle until the lower arm begins to move. 4. Attach a piece of safety wire to the front wheel spindle and secure the spindle to the frame. 5. Remove the bolt and nut. 6. Remove the front suspension upper arm. 1 Remove the two nuts and bolts. 2 Remove the front suspension upper arm. Installation 1. NOTE: Do not tighten the front suspension upper arm nuts and bolts until the vehicle's suspension is at curb height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6472 To install, reverse the removal procedure. 2. Check wheel alignment. Adjust if necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6473 Control Arm: Service and Repair Rear With Air Suspension Rear Suspension Removal CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, Jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off. 2. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a static, level ground position (curb height). 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 5. Use the special tool 014-0094 or equivalent to support the rear axle. 6. WARNING: Do not remove an air spring under any circumstances when there is air pressure in the air spring. Do not remove any components supporting an air spring without exhausting the air. Release the air pressure from the air springs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6474 7. Remove and discard the rear suspension lower arm pivot bolt and nut from the axle bracket. 8. Remove and discard the rear suspension lower arm pivot bolt and nut from the frame bracket. Remove the rear suspension lower arm. Installation 1. NOTE: The rear suspension lower arm bolts must be tightened with the vehicle at curb height. NOTE: The rear suspension lower arms are interchangeable from side-to-side with "OUTBOARD" stamped on the side of the arm for positioning during installation. Position the rear suspension lower arm to the frame bracket and install a new pivot bolt and nut. Insert the bolt so the nut faces inboard. Do not tighten at this time. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6475 2. Position the rear suspension lower arm to the axle bracket and install a new pivot bolt and nut. Insert the bolt so the nut faces outboard. Do not tighten at this time. 3. Raise the axle assembly to the position that compresses the shock absorber to the previously established alignment mark (curb height). 4. Tighten the rear suspension lower arm to the frame bracket pivot bolt. 5. Tighten the rear suspension lower arm to axle bracket pivot bolt. 6. Remove the special tool 014-0094 or equivalent. 7. Lower the vehicle. 8. Turn the air suspension service switch on. 9. Inflate the air springs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6476 Without Air Suspension Rear Suspension Removal CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a static, level ground position (curb height). 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. Use the special tool 014-0094 or equivalent to support the rear axle. 5. Remove and discard the rear suspension lower arm pivot bolt and nut from the axle bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6477 6. Remove and discard the rear suspension lower arm pivot bolt and nut from the frame bracket. Remove the rear suspension lower arm. Installation 1. NOTE: The rear suspension lower arm bolts must be tightened with the vehicle at curb height. NOTE: The rear suspension lower arms are interchangeable from side-to-side with "OUTBOARD" stamped on the side of the arm for positioning during installation. Position the rear suspension lower arm to the frame bracket and install a new pivot bolt and nut. Insert the bolt so the nut faces inboard. Do not tighten at this time. 2. Position the rear suspension lower arm to the axle bracket and install a new pivot bolt and nut. Insert the bolt so the nut faces outboard. Do not tighten at this time. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6478 3. Raise the axle assembly to the position that compresses the shock absorber to the previously established alignment mark (curb height). 4. Tighten the rear suspension lower arm to the frame bracket pivot bolt. 5. Tighten the rear suspension lower arm to axle bracket pivot bolt. 6. Remove the special tool 014-0094 or equivalent. 7. Lower the vehicle. With Air Suspension Rear Suspension Removal CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6479 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off. 2. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a static, level ground position (curb height). 3. Raise and support the vehicle. 4. Use the special tool 014-0094 or equivalent to support the rear axle. 5. WARNING: Do not remove an air spring under any circumstances when there is air pressure in the air spring. Do not remove any components supporting an air spring without exhausting the air. Release the air pressure from the air springs. 6. CAUTION: Do not use excessive force when removing the pivot bolt and flag nut on the right upper suspension arm to axle bracket. Damage to the brake line can occur. Remove and discard the rear suspension upper arm pivot bolt and nut from the axle bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6480 7. Remove and discard the rear suspension upper arm pivot bolt and nut from the frame bracket. Remove the rear suspension upper arm. Installation 1. NOTE: The rear suspension upper arm bolts must be tightened with the vehicle at curb height. NOTE: The rear suspension upper arms are interchangeable from side-to-side with "FRONT" and "OUTBOARD" stamped on the side of the arms for positioning during installation. Position the rear suspension upper arm to the frame bracket and install a new pivot bolt and nut. Insert the bolt so the nut faces inboard. Do not tighten at this time. 2. Position the rear suspension upper arm to the axle bracket and install a new pivot bolt and nut. Insert the bolt so the nut faces outboard. Do not tighten at this time. 3. Raise the axle assembly to the position that compresses the shock absorber to the previously established alignment mark (curb height). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6481 4. Tighten the bolt. 5. Tighten the bolt. 6. Remove the special tool 01-0094 or equivalent. 7. Lower the vehicle. 8. Turn the air suspension service switch on. 9. Inflate the air springs. Without Air Suspension Rear Suspension Removal CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6482 parts. 1. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a static, level ground position (curb height). 2. Raise and support the vehicle. 3. Use the special tool 014-0094 or equivalent to support the rear axle. 4. CAUTION: Do not use excessive force when removing the pivot bolt and flag nut on the right upper suspension arm to axle bracket. Damage to the brake line can occur. Remove and discard the rear suspension upper arm pivot bolt and nut from the axle bracket. 5. Remove and discard the rear suspension upper arm pivot bolt and nut from the frame bracket. Remove the rear suspension upper arm. Installation 1. NOTE: The rear suspension upper arm bolts must be tightened with the vehicle at curb height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6483 NOTE: The rear suspension upper arms are interchangeable from side-to-side with "FRONT" and "OUTBOARD" stamped on the side of the arms for positioning during installation. Position the rear suspension upper arm to the frame bracket and install a new pivot bolt and nut. Insert the bolt so the nut faces inboard. Do not tighten at this time. 2. Position the rear suspension upper arm to the axle bracket and install a new pivot bolt and nut. Insert the bolt so the nut faces outboard. Do not tighten at this time. 3. Raise the axle assembly to the position that compresses the shock absorber to the previously established alignment mark (curb height). 4. Tighten the bolt. 5. Tighten the bolt. 6. Remove the special tool 01-0094 or equivalent. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6484 7. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Page 6485 Control Arm: Tools and Equipment Rear Suspension Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications Lateral Stabilizer Rod: Specifications NOTE: The rear suspension lateral arm pivot bolts and the Watts link pivot nut must be tightened with the vehicle at curb height. Watts Link Pivot Stud ............................................................................................................................................ ............................................. 270 Nm (199 ft. lbs.) Pivot Nut .............................................................. ............................................................................................................................. 250 Nm (184 ft. lbs.) Lateral Arm Arms To Watts Link ............................................................................................................................. ................................................ 92 Nm (68 ft. lbs.) Arms To Frame Brackets ...................................... .............................................................................................................................. 103 Nm (76 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly Lateral Stabilizer Rod: Service and Repair Disassembly and Assembly With Air Suspension Disassembly CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Remove the lateral arm and Watts link pivot assembly. 2. Mark the position of the lateral arms on the Watts link pivot for positioning during installation. 3. Mark the position of the height sensor mounting bracket to the lateral arm for positioning during installation. 4. Remove the height sensor mounting bracket retaining nuts and remove the bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6491 5. Remove the lateral arm retaining nuts from the Watts link pivot and remove the arms. Assembly 1. CAUTION: If installing a new Watts link pivot or lateral arms, mark the new part in the same place the old part was marked during disassembly. Make sure the marks are lined up correctly during assembly. Failure to do so can cause premature wear of the bushings or, on a vehicle equipped with air suspension, incorrect ride height, resulting in poor ride and handling. CAUTION: If installing a new Watts link pivot, make sure it is facing the right direction. "FRONT" is stamped on the Watts link pivot. Failure to do so will result in damage to the Watts link. Follow the disassembly procedure in reverse order. Without Air Suspension Disassembly CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Remove the lateral arm and Watts link pivot assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6492 2. Mark the position of the lateral arms on the Watts link pivot for positioning during installation. 3. Remove the lateral arm retaining nuts from the Watts link pivot and remove the arms. Assembly 1. CAUTION: If installing a new Watts link pivot or lateral arms, mark the new part in the same place the old part was marked during disassembly. Make sure the marks are lined up correctly during assembly. Failure to do so can cause premature wear of the bushings or, on a vehicle equipped with air suspension, incorrect ride height, resulting in poor ride and handling. CAUTION: If installing a new Watts link pivot, make sure it is facing the right direction. "FRONT" is stamped on the Watts link pivot. Failure to do so will result in damage to the Watts link. Follow the disassembly procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6493 Lateral Stabilizer Rod: Service and Repair Replacement With Air Suspension Rear Suspension Removal CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off. 2. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a static, level ground position (curb height). 3. Raise and support the vehicle. 4. Use the special tool 014-0094 or equivalent to support the rear axle. 5. WARNING: Do not remove an air spring under any circumstances when there is air pressure in the air spring. Do not remove any components supporting an air spring without exhausting the air. Release the air pressure from the air springs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6494 6. Disconnect the height sensor from the mounting bracket. 7. Remove and discard both lateral arm assembly pivot bolts and nuts. 8. NOTE: The Watts link pivot stud is coated with a dry adhesive and must be replaced whenever the pivot nut or stud is loosened or removed with a new Watts link pivot nut and stud service kit. NOTE: If the Watts link pivot stud on the axle assembly loosens while removing the pivot nut, continue to loosen the pivot stud until you can insert an open end wrench to hold the pivot stud. While holding the pivot stud, remove the pivot nut. Remove and discard the Watts link pivot nut. 9. Lower the axle until the Watts link is free of the pivot stud. Remove the lateral arm assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6495 10. Remove and discard the Watts link pivot stud. Installation 1. Install a new Watts link pivot stud. 2. NOTE: The rear suspension lateral arm pivot bolts and the Watts link pivot nut must be tightened with the vehicle at curb height. Install the lateral arm assembly on the pivot stud making sure the flange of the right arm faces the front of the vehicle. 3. Raise the axle until the lateral arm assembly aligns with the frame brackets and install new pivot bolts and nuts. Do not tighten at this time. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6496 4. Raise the axle assembly to the position that compresses the shock absorber to the previously established alignment mark (curb height). 5. Tighten both bolts. 6. Tighten the nut. 7. Connect the height sensor to the mounting bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6497 8. Remove the special tool 014-0094 or equivalent. 9. Lower the vehicle. 10. Turn the air suspension service switch on. 11. Inflate the air springs. Without Air Suspension Rear Suspension Removal CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a static, level ground position (curb height). 2. Raise and support the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6498 3. Use the special tool 014-0094 or equivalent to support the rear axle. 4. Remove and discard both lateral arm assembly pivot bolts and nuts. 5. NOTE: The Watts link pivot stud is coated with a dry adhesive and must be replaced whenever the pivot nut or stud is loosened or removed with a new Watts link pivot nut and stud service kit. NOTE: If the Watts link pivot stud on the axle assembly loosens while removing the pivot nut, continue to loosen the pivot stud until you can insert an open end wrench to hold the pivot stud. While holding the pivot stud, remove the pivot nut. Remove and discard the Watts link pivot nut. 6. Lower the axle until the Watts link is free of the pivot stud. Remove the lateral arm assembly. 7. Remove and discard the Watts link pivot stud. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6499 Installation 1. Install a new Watts link pivot stud. 2. NOTE: The rear suspension lateral arm pivot bolts and the Watts link pivot nut must be tightened with the vehicle at curb height. Install the lateral arm assembly on the pivot stud making sure the flange of the right arm faces the front of the vehicle. 3. Raise the axle until the lateral arm assembly aligns with the frame brackets and install new pivot bolts and nuts. Do not tighten at this time. 4. Raise the axle assembly to the position that compresses the shock absorber to the previously established alignment mark (curb height). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6500 5. Tighten both bolts. 6. Tighten the nut. 7. Remove the special tool 014-0094 or equivalent. 8. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Page 6501 Special Tool Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6506 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6507 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Retaining Screws ................................................................................................................................. ..................................... 2.3-3.3 Nm (20-29 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6511 Suspension Control Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6512 Suspension Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6513 Suspension Control Module: Description and Operation A microprocessor controls the air suspension system. The microprocessor and its supporting hardware are contained in the air suspension control module. The air suspension control module responds to signals from various sensors in the vehicle to maintain the programmed ride height while the vehicle is either moving or stopped. The air suspension control module accomplishes this by opening and closing solenoid valves to control the amount of air in the air spring(s). The air suspension control module turns on the compressor by applying voltage through the compressor relay to inflate the air spring(s) and raise the vehicle. The air suspension control module opens the vent solenoid to lower the vehicle by releasing air from the air spring(s)in response to signal inputs from the air suspension height sensor(s). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6514 Suspension Control Module: Service and Repair Removal WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Pull out the lower instrument panel insulator. 1 Remove the pushpins. 2 Pull out the lower instrument panel insulator. 4. Remove the lower instrument panel insulator. 1 Disconnect the power point. 2 Disconnect the courtesy lamp. 3 Remove the lower instrument panel insulator. 5. Remove the rear air suspension control module. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the rear air suspension control module. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6515 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications Ride Height Sensor: Specifications Mounting Bracket To Lateral Arm ........................................................................................................................................................... 14 Nm (10 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6520 Ride Height Sensor: Description and Operation The air suspension height sensor sends signals to the air suspension control module. There are three possible conditions that the air suspension control module interprets from the signals of the air suspension height sensors. The conditions are trim height, below trim height, or above trim height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6521 Ride Height Sensor: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Turn the air suspension switch off. 3. Raise and support the vehicle. 4. Disconnect the air suspension height sensor electrical connector. 5. Remove the air suspension height sensor. ^ Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Shock Absorber Electronic Steering Sensor Screws ...................................................................................................................... ............................................. 1 Nm (9 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6525 Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module to avoid overcompensation of the air suspension during turns. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6526 Steering Angle Sensor: Service and Repair Removal 1. Remove the screws. 2. Remove the sound panel. 3. Remove the finish panel. 4. Remove the knee bolster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6527 5. Remove the bracket. 6. Remove the sensor. 1 Disconnect the wiring. 2 Remove the screws. 3 Remove the sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation Suspension Mode Switch: Description and Operation CAUTION: The air suspension switch must be turned to the OFF position when the vehicle is hoisted, jacked, towed, jump started, or raised off the ground, to avoid unnecessary operation of the system and possible damage to the air suspension system components. The air suspension switch provides a signal to the air suspension control module in the ON position to activate the system to maintain the programmed vehicle height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation > Page 6531 Suspension Mode Switch: Service and Repair Removal WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury. 1. Turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Peel back the luggage compartment trim. 1 Remove the pushpins. 2 Peel back the luggage compartment trim. 4. Remove the air suspension switch. 1 From behind the quarter panel reinforcement, depress the clips. 2 Remove the air suspension switch. 5. Disconnect the electrical connector. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair Spindle: Service and Repair Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. Remove the cotter pin and nut. Discard the cotter pin. 5. Using the special tool, disconnect the tie-rod end from the front wheel spindle. 6. CAUTION: Do not remove the lower ball joint nut at this time. The nut will retain the lower ball joint into the wheel spindle, preventing the spring from flying out and causing personal injury or damage to the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Page 6535 Disconnect the lower ball joint from the front wheel spindle. 1 Loosen the nut, leaving at least three threads engaged in the ball joint. 2 Using a hammer, sharply rap on the front wheel spindle until the lower ball joint disconnects from the spindle. 7. Place a suitable jack stand under the front suspension lower arm. Lower the vehicle until the front suspension lower arm begins to move. 8. Remove the ABS sensor. 1 Remove the bolt. 2 Remove the ABS sensor. 9. Remove the stabilizer bar link from the front wheel spindle. 1 Remove the nut. 2 Remove the link. 10. NOTE: The lower control arm ball joint nut is coated with a dry adhesive and a new nut must be installed whenever the nut is loosened or removed. Remove the lower ball joint nut. Discard the nut. 11. Remove the front wheel spindle. 1 Remove the pinch bolt and nut. 2 Raise the front suspension upper arm. 3 Remove the front wheel spindle. 12. NOTE: If a new front wheel spindle is to be installed, the wheel hub and bearing and the brake disc shield will have to be removed from the spindle. Remove the wheel hub and bearing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Page 6536 13. Remove the front brake disc shield. 1 Using a 3/16 drill bit, remove the rivets. 2 Remove the brake disc shield. Installation 1. NOTE: If the front brake disc shield and the wheel hub and bearing were removed, they will have to be installed. Install the front brake disc shield. 1 Position the front brake disc shield. 2 Install the rivets. 2. Install the wheel hub and bearing. 3. NOTE: The lower control arm ball joint nut is coated with a dry adhesive and a new nut must be installed whenever the nut is loosened or removed. Install the front wheel spindle. 1 Position the front wheel spindle onto the lower ball joint. 2 Install the new nut finger tight. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Page 6537 4. Connect the upper arm to the spindle. 1 Position the upper ball joint into the front wheel spindle. 2 Install the pinch bolt and nut. 5. Tighten the nut. 6. Install the stabilizer bar link. 1 Position the stabilizer bar link. 2 Install the nut. 7. Remove the jack stand. 8. Install the tie-rod end. 1 Position the tie-rod end. 2 Install the nut. 3 Install a new cotter pin. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Page 6538 9. Install the ABS sensor. 1 Position the ABS sensor. 2 Install the bolt. 10. Install the front brake disc. 11. Install the wheel and tire assembly. 12. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Page 6539 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair Stabilizer Bushing: Service and Repair Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Raise and support the vehicle. 2. NOTE: Both the left side and the right side stabilizer bar bushings are removed the same way. Only the right side is shown. Remove the stabilizer bar bracket. 1 Remove the nuts. 2 Remove the bracket. 3. Remove the stabilizer bar bushing. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Retaining Nuts Front To Spindle ........................................................................................................................................... ........................................... 30 Nm (22 ft. lbs.) To Bar ........................................................................ ..................................................................................................................... 55 Nm (41 ft. lbs.) Rear To Frame ............................................................................................................................................. ........................................... 20 Nm (15 ft. lbs.) To Bar ........................................................................ ..................................................................................................................... 20 Nm (15 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Link: Service and Repair Front Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Raise and support the vehicle. 2. Remove the front wheel and tire assemblies. 3. NOTE: Both the left side and the right side stabilizer bar link are removed the same way. Only the right side is shown. Disconnect the front stabilizer bar. 1 Remove the nut. 2 Disconnect the front stabilizer bar. 4. Remove the stabilizer bar link. 1 Remove the nut. 2 Remove the stabilizer bar link. Installation 1. NOTE: Both the left side and the right side stabilizer bar link are installed the same way. Only the right side is shown. Install the stabilizer bar link. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 6549 1 Position the stabilizer bar link. 2 Install the nut. 2. Connect the front stabilizer bar. 1 Position the front stabilizer bar. 2 Install the nut. 3. Install the front wheel and tire assemblies. 4. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 6550 Stabilizer Link: Service and Repair Rear With Air Suspension Rear Suspension Removal CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off. 2. Raise and support the vehicle. 3. Use the special tool 014-0094 or equivalent to support the rear axle. 4. WARNING: Do not remove an air spring under any circumstances when there is air pressure in the air spring. Do not remove any components supporting an air spring without exhausting the air. Release the air pressure from the air springs. 5. Remove both stabilizer bar link lower retaining nuts and bushings. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 6551 6. Remove both stabilizer bar link upper retaining nuts and bushings. Remove the links. 7. Remove both stabilizer bar mounting bracket bolts. Remove the brackets and the stabilizer bar. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 6552 2. Inflate the air springs. Without Air Suspension Rear Suspension Removal CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Raise and support the vehicle. 2. Use the special tool 014-0094 or equivalent to support the rear axle. 3. Remove both stabilizer bar link lower retaining nuts and bushings. 4. Remove both stabilizer bar link upper retaining nuts and bushings. Remove the links. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 6553 5. Remove both stabilizer bar mounting bracket bolts. Remove the brackets and the stabilizer bar. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications Air Dryer: Specifications Retaining Bolts .................................................................................................................................... ........................................... 2-3 Nm (18-27 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications > Page 6558 Air Dryer: Service and Repair Removal 1. Remove the air compressor. 2. Remove the air compressor drier. 1 Remove the screw. 2 Rotate 90° to unlock then remove the air compressor drier. Installation 1. NOTE: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair Air Line: Service and Repair NOTE: A soapy water solution can be applied to the air lines to verify the location of air leaks. 1. If a leak is detected in an air line, it can be repaired by carefully making a good, clean, straight cut. Trim back the outer covering of the air line 16-20 mm (0.63-0.78 inch) to reveal the white inner line. Install a repair fitting and wrap securely with electrical tape. 2. If multiple leaks are detected, replace the entire air line. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Locations > Page 6565 Air Spring: Description and Operation WARNING: Never rotate an air spring solenoid valve to the release slot in the air spring end cap fitting until all pressurized air has escaped from the air spring to prevent vehicle damage or personal injury. The air spring solenoid valve allows air to enter and exit the rear air springs during height adjustment operations. The air spring solenoid valve is electrically operated and controlled by the air suspension control module. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Filling or Refolding Air Spring: Service and Repair Air Spring Filling or Refolding AIR SPRING FILL - REFOLD WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. CAUTION: Do not clamp any portion of the air spring piston. 1. Place air spring on flat surface. 2. Remove air spring solenoid to expand collapsed air bag. 3. Push membrane down over piston to correct height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Filling or Refolding > Page 6568 4. Install air spring solenoid to help maintain correct height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Filling or Refolding > Page 6569 Air Spring: Service and Repair Replacement Removal WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. WARNING: Disconnecting an air line that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. 1. WARNING: ^ Do not attempt to install or inflate any rear air spring that has become unfolded to prevent vehicle damage or personal injury. ^ Failure to observe the procedures may result in a sudden failure of the air spring or suspension system ^ Any rear spring which is unfolded must be refolded prior to being installed in a vehicle. ^ The air spring refolding procedure should only be used for an air spring which has never supported the vehicle's weight while in the improperly folded position. ^ Improperly folded air springs found on vehicles during pre-delivery inspection or after use must be replaced. ^ Do not attempt to inflate any air spring which has been collapsed while uninflated from the rebound hanging position to the jounce stop. ^ When installing a new air spring, care must be taken not to apply a load to the suspension until springs have been inflated using the air spring fill procedure. ^ After inflating an air spring in hanging position, it must be inspected for proper shape. NOTE: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. Deflate the air suspension system. 2. WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury. Turn the air suspension switch off. 3. Raise and support the vehicle. 4. Remove the rear air spring retainer. 5. Lift the bottom of the air spring off the rear axle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Filling or Refolding > Page 6570 6. Remove the air spring. 1 Disconnect the electrical connector. 2 Push on the red air line retaining ring and disconnect the air line. 3 Remove the air spring. Installation 1. CAUTION: To avoid damage to the air spring, do not allow suspension to compress before the spring is inflated. Install the air spring. 1 Position the air spring assembly in the frame seat. 2 Install the spring retainer clip. 2. Seat the bottom of the air spring on the rear axle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Filling or Refolding > Page 6571 3. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Connect the air spring solenoid valve. 1 Connect the electrical connector. 2 Connect the air line. 3 Make sure air spring is in the proper shape with no folds or creases. 4. Refill the air springs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications Compressor/Pump: Specifications Retaining Bolts .................................................................................................................................... ................................... 7.6-10.4 Nm (68-88 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 6575 Compressor/Pump: Description and Operation NOTE: The compressor contains a thermal overload circuit breaker. The circuit breaker automatically resets after a cool down period and after being if tripped by excessive compressor motor heat. The air compressor assembly consists of the compressor pump, electric motor and vent solenoid (must be installed as an assembly). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 6576 Compressor/Pump: Service and Repair Removal WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. WARNING: Disconnecting an air line that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury. 1. Turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Remove the Engine Air Cleaner (ACL). 4. Remove the air compressor and air compressor drier cover. 1 Remove the pushpins. 2 Remove the air compressor and air compressor drier cover. 5. Remove the snorkel pushpin and remove the snorkel. 6. Remove the air compressor and air compressor drier. 1 Compress the quick connect locking ring and pull out the air line. 2 Disconnect the electrical connector. 3 Remove the three bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 6577 4 Remove the air compressor and air compressor drier. Installation 1. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. NOTE: After installing the air compressor, it is necessary to inflate the air suspension system. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6581 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6582 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Diagnostic Connector, Suspension > Component Information > Locations Diagnostic Connector: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Diagnostic Connector, Suspension > Component Information > Locations > Page 6586 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Functional Level Control Solenoid Valve: Service and Repair Functional Removal WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. WARNING: Disconnecting an air line that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. 1. Remove the air spring. 2. CAUTION: Remove any dirt or other debris from the air spring assembly before removing the air spring solenoid. NOTE: The air spring solenoid valve has a two stage solenoid valve pressure relief fitting similar to a radiator cap. Release the air pressure. 1 Rotate the air spring solenoid valve counterclockwise to the first stop. 2 Pull the air spring solenoid valve out to the stop. 3. WARNING: Do not fully release solenoid air valve until air is completely bled from the air spring to prevent injury. Rotate the air spring solenoid valve counterclockwise to the second stop and remove from the solenoid valve housing. Installation 1. NOTE: Check the solenoid valve O-rings for abrasion or cuts. Replace O-rings as required using air spring connector repair kit. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 6591 NOTE: Lightly apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the O-rings. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 6592 Level Control Solenoid Valve: Service and Repair Non-Functional Removal WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. NOTE: The air spring solenoid has a two-stage pressure relief fitting similar to a radiator cap. 1. Turn the air suspension switch off. 2. Raise and support the vehicle. 3. Disconnect the air spring solenoid electrical connector and air line. 1 Disconnect the electrical connector. 2 Compress the quick connect locking ring and pull out the air line. 4. CAUTION: Remove any dirt or other debris from the air spring prior to removing the air spring solenoid from the air spring. Remove the air spring solenoid clip. 5. Rotate the air spring solenoid out of the air spring to the first detent to release the air from the air spring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 6593 6. Twist the solenoid valve and remove. Installation 1. NOTE: Be sure the new air spring solenoid is fully seated into both stages of the air spring. NOTE: Check the solenoid valve O-rings for abrasion or cuts. Replace O-rings as required using air spring connector repair kit. NOTE: Lightly apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the O-rings. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse removal procedure. ^ After installing the solenoid, it is necessary to inflate the air suspension system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications Ride Height Sensor: Specifications Mounting Bracket To Lateral Arm ........................................................................................................................................................... 14 Nm (10 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6597 Ride Height Sensor: Description and Operation The air suspension height sensor sends signals to the air suspension control module. There are three possible conditions that the air suspension control module interprets from the signals of the air suspension height sensors. The conditions are trim height, below trim height, or above trim height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6598 Ride Height Sensor: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Turn the air suspension switch off. 3. Raise and support the vehicle. 4. Disconnect the air suspension height sensor electrical connector. 5. Remove the air suspension height sensor. ^ Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Retaining Screws ................................................................................................................................. ..................................... 2.3-3.3 Nm (20-29 inch lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 6602 Suspension Control Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 6603 Suspension Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 6604 Suspension Control Module: Description and Operation A microprocessor controls the air suspension system. The microprocessor and its supporting hardware are contained in the air suspension control module. The air suspension control module responds to signals from various sensors in the vehicle to maintain the programmed ride height while the vehicle is either moving or stopped. The air suspension control module accomplishes this by opening and closing solenoid valves to control the amount of air in the air spring(s). The air suspension control module turns on the compressor by applying voltage through the compressor relay to inflate the air spring(s) and raise the vehicle. The air suspension control module opens the vent solenoid to lower the vehicle by releasing air from the air spring(s)in response to signal inputs from the air suspension height sensor(s). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 6605 Suspension Control Module: Service and Repair Removal WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Pull out the lower instrument panel insulator. 1 Remove the pushpins. 2 Pull out the lower instrument panel insulator. 4. Remove the lower instrument panel insulator. 1 Disconnect the power point. 2 Disconnect the courtesy lamp. 3 Remove the lower instrument panel insulator. 5. Remove the rear air suspension control module. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the rear air suspension control module. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 6606 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Description and Operation Suspension Mode Switch: Description and Operation CAUTION: The air suspension switch must be turned to the OFF position when the vehicle is hoisted, jacked, towed, jump started, or raised off the ground, to avoid unnecessary operation of the system and possible damage to the air suspension system components. The air suspension switch provides a signal to the air suspension control module in the ON position to activate the system to maintain the programmed vehicle height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Description and Operation > Page 6610 Suspension Mode Switch: Service and Repair Removal WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury. 1. Turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Peel back the luggage compartment trim. 1 Remove the pushpins. 2 Peel back the luggage compartment trim. 4. Remove the air suspension switch. 1 From behind the quarter panel reinforcement, depress the clips. 2 Remove the air suspension switch. 5. Disconnect the electrical connector. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Warning Indicator > Component Information > Description and Operation Suspension Warning Indicator: Description and Operation The CHECK AIR SUSPENSION warning indicator illuminates when a concern in the air suspension system is detected or when the air suspension switch is in the OFF position. During prove-out, when a concern is detected or the air suspension switch is OFF, an audible tone will sound and the CHECK AIR SUSPENSION warning indicator will flash on and off for five seconds. The CHECK AIR SUSPENSION warning indicator will then remain illuminated until the concern is corrected or the air suspension switch is switched ON. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing Suspension Spring ( Coil / Leaf ): Customer Interest A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 6622 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 6623 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At Extension Housing Article No. 99-18-1 09/06/99 ^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY ^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY FORD: 1999 CROWN VICTORIA ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid leak from the extension housing seal area. This may be due to extended high speed operation which may cause the extension housing bushing or seal to walk/spin out due to excessive driveshaft flexing. ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised driveshaft does not flex as much during sustained high speed operation and should reduce the possibility of fluid leaks. Refer to the following Service Procedure for details SERVICE PROCEDURE 1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will have pink/blue/orange stripes. 2. If the bushing is found to be damaged, remove the driveshaft and transmission extension housing per the appropriate Workshop Manual Section. 3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket (F7AZ-7086-A) following the procedure outlined in the Workshop Manual. 4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the revised MMC Driveshaft (XW7Z-4602-AA). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 6629 NOTE THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE PERFORMED (FIGURE 2). 5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised "GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details. 6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM) calibration. Refer to Step 7. 7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph). Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS). 8. Verify transmission fluid level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 6630 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F5UZ-7A039-A Extension Housing Assembly F7AZ-7086-A Gasket XW7Z-4602-AA Driveshaft F8AZ-5560-GA Rear Coil Springs OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991801A Replace Extension And 1.6 Hrs. Driveshaft Housing Assembly (Do Not Use With Operation B) 991801B Replace Driveshaft 0.7 Hr. Assembly Only If Required (Do Not Use With Operation A) 991801C Replace Rear Springs 0.9 Hr. 991801D Inspect For Calibration 0.3 Hr. 991801E Reprogram Powertrain 0.3 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE 4602 02 OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Page 6631 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Spring ( Coil / Leaf ): Service and Repair Front Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Mark the relative position of the front suspension lower arm to the frame with the vehicle in a static, level ground position (curb height). 2. Raise and support the vehicle. 3. Remove the front wheel and tire assemblies. 4. Remove the shock absorber lower mounting bolts 5. Remove the front shock absorber. 1 Remove the nut, retainer and grommet. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6634 2 Remove the shock absorber. 6. Using the special tool, compress the front coil spring until it is free in its front spring insulator. 7. Remove the front coil spring. 1 Remove the bolts and nuts. 2 Pivot the front suspension lower arm. Remove the front coil spring. Installation 1. With the front coil spring compressed, position the spring on the lower control arm. 2. NOTE: Do not tighten the front suspension lower arm bolts until the suspension is at curb height. Install the front suspension lower arm. 1 Position the front suspension lower arm. 2 Install the bolts and nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6635 3. Make sure the front spring insulator is properly seated and remove the special tool 204-D00 (D78P-5310-A). 4. Install the shock absorber. 1 Position the shock absorber through the upper shock mount. 2 Install the grommet, retainer and nut, and tighten. 5. Install the shock absorber lower mounting bolts. 6. Position a jack stand under the front suspension lower arm and raise the suspension until the marks on the front suspension lower arm and the frame made in removal, step 1 are aligned (curb height). 7. Tighten the bolts. 8. Lower the suspension and remove the jack stand. 9. Install the front wheel and tire assemblies. 10. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6636 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Rear Suspension Removal CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Mark the rear shock absorber relative to the protective sleeve with the vehicle in a static, level ground position (curb height). 2. Raise the vehicle on a hoist. 3. Remove both wheel and tire assemblies. 4. Disconnect the stabilizer bar from the stabilizer bar links. 1 Remove the nuts and the bushings. 2 Rotate the stabilizer bar off the links. 5. Use the special tool 014-0094 or equivalent to support the rear axle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6637 6. Remove the nuts and bolts and disconnect the lateral arms from the frame. Discard the nuts and bolts. 7. WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing. Failure to follow these instructions can result in personal injury. Remove the nuts and disconnect the shock absorbers from the axle. Discard the nuts. 8. Carefully lower the special tool. 9. Remove the springs and spring insulators. Installation 1. Inspect the spring insulators for wear or damage. Install new insulators if necessary. 2. Install the spring insulators on the springs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6638 3. Install the springs and the spring insulators in the vehicle. Make sure the springs are properly seated. 4. Raise the axle using the special tool. 5. Connect the shock absorbers to the axle and install new nuts. 6. Connect the lateral arms to the frame and install new bolts and nuts. Do not tighten at this time. 7. Using the special tool, raise the axle until the shock absorber is compressed to the previously established alignment mark (curb height). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6639 8. Tighten both bolts. 9. Lower the axle and remove the special tool. 10. Connect the stabilizer bar to the stabilizer bar links. 1 Rotate the stabilizer bar onto the links and install the bushings. 2 Install the nuts. 11. Install the wheel and tire assemblies. 12. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 6640 Suspension Spring ( Coil / Leaf ): Tools and Equipment Rear Suspension Special Tool Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications Mounting Bolts/Nuts Front Upper ................................................................................................................................................... ........................................... 40 Nm (30 ft. lbs.) Lower ......................................................................... ..................................................................................................................... 15 Nm (11 ft. lbs.) Rear Upper ................................................................................................................................................... ........................................... 40 Nm (30 ft. lbs.) Lower ......................................................................... ..................................................................................................................... 90 Nm (66 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > With Air Suspension Suspension Strut / Shock Absorber: Service and Repair With Air Suspension Rear Suspension Removal WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing. Failure to follow these instructions can result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off. 2. Raise and support the vehicle. 3. Use the special tool 014-0094 or equivalent to support the rear axle. 4. WARNING: Do not remove an air spring under any circumstances when there is air pressure in the air spring. Do not remove any components supporting an air spring without exhausting the air. Release the air pressure from the air springs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > With Air Suspension > Page 6646 5. NOTE: Replace shock absorbers individually as required. It is not necessary to replace in pairs. NOTE: To assist in removing the upper attachment on shock absorbers, use a plastic dust tube and place an open end wrench on the hex stamped into the dust tube's metal cap. For shock absorbers with a steel dust tube, simply grasp the tube to prevent stud rotation when loosening the retaining nut. Remove the shock absorber upper retaining nut, washer and insulator from the stud on the upper side of the frame. 6. Remove and discard the nut. Disconnect the shock absorber lower stud from the mounting bracket on the rear axle assembly. Installation 1. To install, reverse the removal procedure. 2. Inflate the air springs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > With Air Suspension > Page 6647 Suspension Strut / Shock Absorber: Service and Repair Without Air Suspension Rear Suspension Removal WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing. Failure to follow these instructions can result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to ensure proper retention of these parts. 1. Raise and support the vehicle. 2. Use the special tool 014-0094 or equivalent to support the rear axle. 3. NOTE: Replace shock absorbers individually as required. It is not necessary to replace in pairs. NOTE: To assist in removing the upper attachment on shock absorbers, use a plastic dust tube and place an open end wrench on the hex stamped into the dust tube's metal cap. For shock absorbers with a steel dust tube, simply grasp the tube to prevent stud rotation when loosening the retaining nut. Remove the shock absorber upper retaining nut, washer and insulator from the stud on the upper side of the frame. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > With Air Suspension > Page 6648 4. Remove and discard the nut. Disconnect the shock absorber lower stud from the mounting bracket on the rear axle assembly. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Page 6649 Special Tool Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications Retaining Nuts ..................................................................................................................................... ...................................................... 40 Nm 30 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6657 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6658 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6659 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6660 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6661 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6662 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6663 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6664 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6665 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6666 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6667 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6668 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6669 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6670 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6671 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6672 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6673 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6674 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6675 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6676 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6677 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6678 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6679 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6680 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6681 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6682 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6683 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6684 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6685 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6686 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6687 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6688 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6689 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6690 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6691 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6692 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6693 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6694 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6695 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6696 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6697 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6698 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6699 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6700 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6701 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6702 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6703 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6704 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6705 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6706 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6707 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6708 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6709 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6710 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6711 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6712 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6713 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6714 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6715 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6716 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6717 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6718 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6719 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6720 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6721 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6722 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6723 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6724 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6725 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6726 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6727 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6728 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6729 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6730 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6731 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6732 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6733 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6734 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6735 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6736 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6737 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6738 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6739 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6740 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6741 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6742 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6743 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6744 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6745 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6746 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6747 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6748 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6749 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6750 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6751 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6752 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6753 Wheel Bearing: Testing and Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, install a new wheel hub. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6754 Wheel Bearing: Service and Repair FRONT WHEEL HUB Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. Remove and discard the front hub cap grease seal. 5. CAUTION: The front axle wheel hub retainer must never be reused. If the retainer is reused, it can back off resulting in loss of the front wheel and or damage to the wheel hub and bearing assembly. Remove the front axle wheel hub retainer. Discard the retainer. 6. CAUTION: When removing the wheel hub and bearing, use caution not to damage the ABS sensor lead or the ABS sensor ring. NOTE: The wheel hub and bearing assembly is a slip fit design and should not require a puller to remove. Remove the wheel hub and bearing assembly. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6755 1. CAUTION: When installing the wheel hub and bearing, use extreme caution not to damage the ABS sensor lead or the ABS sensor ring. Install the wheel hub and bearing assembly. 2. Install a new front axle wheel hub retainer. 3. Install a new front hub cap grease seal. 4. Install the brake disc. 5. Install the wheel and tire assembly. 6. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Wheel Hub Retainer ........................................................................................................................................................... 300 Nm (221 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure Technical Service Bulletin # 00S13 Date: 000701 Recall - Vehicle Jacking Procedure SAFETY RECALL 00S13 Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment II ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6769 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6770 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental vehicles are not approved for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage label, and a jack usage and stowage placard will be sent directly to owners, along with instructions on placement of the various pieces. This will be a "no charge" service and customers will be directed to follow the attached instructions for proper placement of the labels and owner guide supplement. Additional owner packages containing the above mentioned items can be ordered by calling the Recall Hotline at 1-800-325-5621. Attachment III - Technical Information OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the vehicle: ^ Tire Change Procedure Supplement. ^ Jack Operating Instructions label. ^ Jack Usage and Stowage label. ^ Jack Usage and Stowage/Tire Changing Instruction placard. The following instructions/illustrations will help locate the proper area for each of these items. TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6771 1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located in the glove compartment. See Figure 1. JACK OPERATING INSTRUCTIONS LABEL PLACEMENT NOTE: The jack may be located under the spare tire or behind the right quarter trim panel. 1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by removing the right quarter trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6772 2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2. JACK USAGE AND STOWAGE LABEL PLACEMENT NOTE: The Jack Usage and Stowage label may be located on the inner right quarter panel or the underside of the spare tire cover. 1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and Stowage label directly over the original label as illustrated. See Figure 3. JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6773 1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing Instruction placard on top of the spare tire as illustrated. See Figure 4. 2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6774 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6775 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure Technical Service Bulletin # 00S13 Date: 000701 Recall - Vehicle Jacking Procedure SAFETY RECALL 00S13 Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment II ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6781 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6782 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental vehicles are not approved for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage label, and a jack usage and stowage placard will be sent directly to owners, along with instructions on placement of the various pieces. This will be a "no charge" service and customers will be directed to follow the attached instructions for proper placement of the labels and owner guide supplement. Additional owner packages containing the above mentioned items can be ordered by calling the Recall Hotline at 1-800-325-5621. Attachment III - Technical Information OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the vehicle: ^ Tire Change Procedure Supplement. ^ Jack Operating Instructions label. ^ Jack Usage and Stowage label. ^ Jack Usage and Stowage/Tire Changing Instruction placard. The following instructions/illustrations will help locate the proper area for each of these items. TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6783 1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located in the glove compartment. See Figure 1. JACK OPERATING INSTRUCTIONS LABEL PLACEMENT NOTE: The jack may be located under the spare tire or behind the right quarter trim panel. 1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by removing the right quarter trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6784 2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2. JACK USAGE AND STOWAGE LABEL PLACEMENT NOTE: The Jack Usage and Stowage label may be located on the inner right quarter panel or the underside of the spare tire cover. 1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and Stowage label directly over the original label as illustrated. See Figure 3. JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6785 1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing Instruction placard on top of the spare tire as illustrated. See Figure 4. 2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6786 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 6787 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 6788 Vehicle Lifting: Description and Operation JACKING WARNING ^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. CAUTION ^ 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. Refer to the Owner Guide when using the jack supplied with the vehicle. ^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer or differential housing. Severe damage to the vehicle could result. ^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to the bumper covers will occur. Lift the vehicle using the Jacking Points procedure. Jacking Points Push the air suspension service switch to the OFF position. To lift the front or either side of the front end, position the floor jack or the hoist under the front frame lift points. To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift points. LIFTING WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION ^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar, rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator. Damage to the suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 6789 ^ Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. Lift the vehicle using the Lifting Points procedure. Lifting Points-Drive-On Lift CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference. Check for interference between the upright flanges of the hoist rails and the underbody. If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to provide clearance. Lifting Points-Two Post Lift CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 6790 Lifting Points-Single-Post Hoist CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 6791 Vehicle Lifting: Service and Repair JACKING WARNING ^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. CAUTION ^ 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. Refer to the Owner Guide when using the jack supplied with the vehicle. ^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer or differential housing. Severe damage to the vehicle could result. ^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to the bumper covers will occur. Lift the vehicle using the Jacking Points procedure. Jacking Points Push the air suspension service switch to the OFF position. To lift the front or either side of the front end, position the floor jack or the hoist under the front frame lift points. To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift points. LIFTING WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION ^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar, rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator. Damage to the suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 6792 ^ Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. Lift the vehicle using the Lifting Points procedure. Lifting Points-Drive-On Lift CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference. Check for interference between the upright flanges of the hoist rails and the underbody. If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to provide clearance. Lifting Points-Two Post Lift CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 6793 Lifting Points-Single-Post Hoist CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear control arms. Severe damage to the vehicle could result. NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post hoist. Lift the vehicle at the applicable lift points. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications Wheel Size .......................................................................................................................................... ...................................................................... 16 x 4.5 Bolt Circle ....................................................... ...................................................................................................................................... 114.3 mm (4.5 inch) Lugs ..................................................................................................................................... ................................................................................................. 5 Offset .............................................. .............................................................................................................................................................. ............ 9 (inset) Tire Usage ................................................................................................................ ............................................................................... T145/80D16 105M Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Wheels: Customer Interest Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Wheels: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 6815 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis Wheels: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis Article No. 01-1-14 01/22/01 ^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) ^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) FORD: 1999-2001 CROWN VICTORIA MERCURY: 1999-2001 GRAND MARQUIS ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph) which may be related to driveshaft, axle, wheels, or their components. ACTION Identify the causal component for the vibration and balance or replace as necessary to eliminate the vibration. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 6820 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 6821 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 6822 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 6823 For Dealerships with An Electronic Vibration Analyzer Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration conditions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 6824 Driveline Vibration Data Sheet OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6829 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6830 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6831 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6832 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6833 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6834 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6835 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6836 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6837 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6838 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6839 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6840 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6841 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6842 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6843 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6844 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6845 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6846 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6847 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6848 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6849 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6850 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6851 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6852 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6853 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6854 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6855 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6856 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6857 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6858 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6859 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6860 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6861 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6862 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6863 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6864 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6865 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6866 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6867 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6868 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6869 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6870 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6871 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6872 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6873 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6874 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6875 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6876 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6877 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6878 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6879 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6880 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6881 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6882 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6883 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6884 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6885 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6886 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6887 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6888 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6889 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6890 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6891 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6892 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6893 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6894 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6895 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6896 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6897 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6898 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6899 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6900 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6901 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6902 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6903 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6904 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6905 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6906 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6907 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6908 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6909 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6910 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6911 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6912 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6913 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6914 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6915 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6916 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6917 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6918 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6919 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6920 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6921 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6922 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6923 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 6929 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis Wheels: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis Article No. 01-1-14 01/22/01 ^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) ^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH) FORD: 1999-2001 CROWN VICTORIA MERCURY: 1999-2001 GRAND MARQUIS ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph) which may be related to driveshaft, axle, wheels, or their components. ACTION Identify the causal component for the vibration and balance or replace as necessary to eliminate the vibration. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 6934 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 6935 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 6936 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 6937 For Dealerships with An Electronic Vibration Analyzer Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration conditions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 6938 Driveline Vibration Data Sheet OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6943 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6944 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6945 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6946 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6947 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6948 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6949 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6950 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6951 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6952 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6953 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6954 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6955 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6956 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6957 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6958 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6959 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6960 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6961 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6962 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6963 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6964 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6965 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6966 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6967 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6968 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6969 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6970 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6971 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6972 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6973 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6974 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6975 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6976 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6977 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6978 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6979 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6980 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6981 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6982 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6983 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6984 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6985 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6986 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6987 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6988 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6989 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6990 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6991 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6992 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6993 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6994 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6995 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6996 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6997 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6998 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6999 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7001 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7002 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7003 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7004 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7005 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7006 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7007 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7008 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7009 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7010 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7011 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7012 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7013 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7014 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7015 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7016 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7017 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7018 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7019 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7020 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7021 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7022 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7023 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7024 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7025 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7026 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7027 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7028 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7029 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7030 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7031 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7032 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7033 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7034 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7035 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7036 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7037 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7038 Wheels: Specifications Bolt Circle ............................................................................................................................................ ................................................. 114.3 mm (4.5 inch) Balance Weights, Max. Per Wheel ............................................................................................................................................ ...................................................... 140 g (5.0 oz.) Per Side ................................................................ ......................................................................................................................................... 70 g (2.5 oz.) Lugs ..................................................................................................................................................... ................................................................................. 5 Offset Steel .................................................................................................................................................... .......................................................................... 11 Aluminum ............................................................. ......................................................................................................................................................... 4.5 Runout, Max Radial .................................................................................................................................................. ............................................. 0.64 mm (0.025 inch) Lateral ................................................................. ............................................................................................................................. 0.89 mm (0.035 inch) Size ...................................................................................................................................................... ......................................................................... 16 x 7 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7039 Wheels: Testing and Inspection TIRE AND WHEEL RUNOUT Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor. Before checking runout, and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm the tires. The extent of the runout is measured with the radial runout gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures. TIRE RUNOUT Measure radial and lateral tire runout at the positions shown in the illustration. Runout should not exceed specifications. WHEEL RUNOUT Measure radial and lateral wheel runout at the positions shown in the illustration. Runout should not exceed specifications. Note that the tire has been removed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks Wheels: Service and Repair Leaks NOTE: Wheel repairs that use welding or peening are not approved. An inner tube is not an acceptable repair for leaking wheels or tires. If the air pressure in a tire mounted on an aluminum wheel is found to be low, perform the following procedure before considering wheel replacement. 1. Remove the tire and wheel assembly, and inspect the wheel for structural damage. If none exists, go to Step 2. If the wheel is damaged, install new. 2. With the tire mounted on the wheel, locate the air leak using a water bath or equivalent method, and mark the location. Check the complete wheel for possible additional leaks. When leaks are marked, dismount the tire marking valve location on the tire for correct indexing. 3. On the tire side of the wheel, thoroughly clean the leaking area with an appropriate cleaner (Professional Choke and Linkage Cleaner E8AZ-19A501-AA or equivalent meeting Ford specification ESR-M14P10-A) or use sandpaper of approximately 80-grit to remove all contamination. Using the sandpaper, score the surface of the leaking area to improve adhesion of the sealer. If the valve stem is close to the area, remove it. 4. Use a clean cloth to remove all cleaner or sanding dust. 5. NOTE: Do not use a torch containing oxyacetylene. Heat the prepared area with a Heat Gun or a propane torch until Aluminum Wheel Repair Compound E7AZ-19554-A or equivalent meeting Ford specification ESA-M4G280-A flows. Apply the hot melt material over the prepared area using a liberal flow and wiping action. Repair is most effective when heat is applied to the brake side of the rim, and the sealer is melted by heat in the metal. 6. Apply only enough heat to melt the sealer, then remove the heat source. After repairing the leak, allow the wheel to cool until it can be handled safety. 7. CAUTION: Use caution when mounting the tire so as not to damage the sealer. Index and assemble the tire and wheel. Inflate the tire to the recommended pressure as indicated on the tire pressure decal. 8. Repeat Step 2 to verify repair. 9. When the repair is completed, balance the assembly and install it on the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 7042 Wheels: Service and Repair Replacement Removal 1. Loosen the lug nuts. 1 Remove the wheel cover or ornament. 2 CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Loosen, but do not remove the lug nuts. 2. CAUTION: Never use the differential housing as a lift point. Raise the vehicle until the tire clears the floor. 3. CAUTION: Do not use heat to loosen a frozen wheel because heat can shorten the life of the wheel and damage the wheel bearings. If the wheel cannot be removed by hand, use a wheel puller to remove the frozen wheel. Remove the wheel and tire from the vehicle. ^ Remove the lug nuts. ^ Remove the wheel and tire. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, resulting in loss of control. Position the wheel and tire on the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 7043 2. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts to specification in a star-pattern sequence. 3. Install the wheel cover or ornament. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7048 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7049 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7050 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7051 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7052 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7053 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7054 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7055 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7056 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7057 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7058 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7059 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7060 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7061 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7062 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7063 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7064 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7065 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7066 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7067 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7068 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7069 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7070 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7071 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7072 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7073 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7074 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7075 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7076 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7077 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7078 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7079 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7080 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7081 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7082 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7083 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7084 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7085 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7086 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7087 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7088 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7089 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7090 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7091 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7092 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7093 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7094 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7095 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7096 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7097 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7098 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7099 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7101 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7102 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7103 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7104 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7105 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7106 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7107 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7108 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7109 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7110 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7111 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7112 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7113 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7114 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7115 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7116 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7117 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7118 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7119 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7120 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7121 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7122 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7123 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7124 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7125 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7126 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7127 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7128 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7129 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7130 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7131 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7132 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7133 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7134 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7135 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7136 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7137 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7138 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7139 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7140 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7141 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7142 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 7143 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 7144 Wheel Bearing: Testing and Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, install a new wheel hub. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 7145 Wheel Bearing: Service and Repair FRONT WHEEL HUB Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. Remove and discard the front hub cap grease seal. 5. CAUTION: The front axle wheel hub retainer must never be reused. If the retainer is reused, it can back off resulting in loss of the front wheel and or damage to the wheel hub and bearing assembly. Remove the front axle wheel hub retainer. Discard the retainer. 6. CAUTION: When removing the wheel hub and bearing, use caution not to damage the ABS sensor lead or the ABS sensor ring. NOTE: The wheel hub and bearing assembly is a slip fit design and should not require a puller to remove. Remove the wheel hub and bearing assembly. Installation Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 7146 1. CAUTION: When installing the wheel hub and bearing, use extreme caution not to damage the ABS sensor lead or the ABS sensor ring. Install the wheel hub and bearing assembly. 2. Install a new front axle wheel hub retainer. 3. Install a new front hub cap grease seal. 4. Install the brake disc. 5. Install the wheel and tire assembly. 6. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Wheel Hub Retainer ........................................................................................................................................................... 300 Nm (221 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts to 115-142 Nm (85-105 ft. lbs.) in a star-pattern sequence. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Special Tools Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. CAUTION: When removing and installing the wheel studs, use extreme caution not to damage the ABS sensor lead or the ABS sensor ring. Using the special tool, press the wheel stud out of the wheel hub and bearing flange. Installation 1. CAUTION: When removing and installing the wheel studs, use extreme caution not to damage the ABS sensor lead or the ABS sensor ring. Position the wheel stud. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7156 2. Install the wheel stud. 1 Install four washers onto the wheel stud. 2 Install reversed wheel nut. Tighten the wheel nut until the wheel stud seats fully onto the wheel hub and bearing flange. 3. Remove the wheel nut and washers. 4. Install the brake disc. 5. Install the wheel and tire assembly. 6. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7157 Wheel Fastener: Service and Repair Rear Special Tools Removal Special Tools 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off (If equipped). 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. Remove rear brake disc. 5. Using the special tool, press the lug bolt from its seat and discard. Installation CAUTION: Never use air tools to install lug bolts. The serrations can be stripped from the stud. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7158 1. Insert a new lug bolt in the hole in the axle flange, making sure serrations are aligned with those in the flange. 2. Place four flat washers over the outside end of the lug bolt, and thread a standard lug nut with the flat side against the washers. 3. Tighten the lug nut until the lug bolt head seats against the back side of the axle flange. 4. Remove the lug nut and washers. 5. Install the rear brake disc. 6. Install the wheel and tire assembly. 7. Lower the vehicle. 8. Turn the air suspension service switch on (If equipped). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 7159 Wheel Fastener: Tools and Equipment Special Tool Special Tool Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Accumulator Mounting Bracket Clamp Bolt ....................................................................................................................................... 6-8 N.m (54-70 Lb-In) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7164 Accumulator HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The suction accumulator/drier is mounted to the right of the vehicle centerline. The inlet tube of the suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet tube of the suction accumulator/drier attaches to the evaporator to compressor suction line. After entering the inlet of the suction accumulator/drier, heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. - As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. - A fitting located on the side of the suction accumulator/drier is used to mount a serviceable low-pressure A/C charge port valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7165 Accumulator HVAC: Service and Repair REMOVAL NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. 1. Recover the refrigerant. 2. Disconnect the evaporator to compressor suction line from the suction accumulator/drier. 3. Disconnect the suction accumulator/drier from the A/C evaporator core. CAUTION: To prevent damage to the fitting and the tube, use a backup wrench when removing the suction accumulator/drier. 4. Remove the screw retaining the A/C accumulator mounting bracket to the A/C evaporator core and remove the suction accumulator/drier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7166 5. Remove the insulation cover from the suction accumulator/drier. 6. Remove the A/C accumulator mounting bracket from the suction accumulator/drier. INSTALLATION 1. To install, reverse the removal procedure. - Service the new suction accumulator/drier with the correct amount of PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: To prevent damage to the fitting and the tube, use a backup wrench when installing the suction accumulator/drier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams Air Door Actuator / Motor: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Air Door Actuator Air Door Actuator / Motor: Description and Operation Air Door Actuator Vacuum Control Motors Vacuum control motors for the Manual A/C system operate the same as the EATC system. With Electronic Automatic Temperature Control Vacuum control motors are used to move the floor/panel and panel/defrost doors. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Air Door Actuator > Page 7173 Air Door Actuator / Motor: Description and Operation Blend Door Motor With Electronic Automatic Temperature Control The A/C electronic blend door actuator is located on the top of the plenum housing. - Its function is to move the air temperature blend door on command from the control assembly. - The A/C electronic blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the air temperature blend door. - A 5 volt signal is applied to the ends of the potentiometer. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the electronic automatic temperature control module and is matched with the wiper voltage of the module potentiometer. The control module then drives the actuator motor in the direction necessary to make the actuator wiper voltage agree with the control module wiper voltage. With Manual A/C The Electronic Blend Door Actuator for the manual A/C system function is similar to the EATC system, except that the temperature potentiometer is controlled by the knob located in the center of the A/C manual control. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator Air Door Actuator / Motor: Service and Repair Air Door Actuator Air Recirculation Door REMOVAL 1. Remove the pin-type connectors and retainer and remove the instrument panel lower insulator. 2. Disconnect the vacuum connector. 3. Remove the control arm clip and the spring. 4. Remove the nuts and remove the vacuum control motor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7176 INSTALLATION 1. To install, reverse the removal procedure. Floor Duct Door REMOVAL 1. Remove the plenum chamber. 2. Reach through the door opening and remove the pin. 3. Remove the screws and remove the vacuum control motor. INSTALLATION 1. To install, reverse the removal procedure. Windshield Defrost Door REMOVAL 1. Disconnect the battery ground cable. 2. Remove the LH lower dash insulator panel and disconnect the lamp. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7177 3. Remove the two pin-type connectors and remove the fill panel. 4. Remove the screws. 5. Disengage the vacuum line. 6. Remove the lighting module. 1 Remove the screws. 2 Disengage the clip. 3 Remove the lighting module. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7178 7. Remove the connectors. 8. Remove the screws and remove the bracket. 9. Remove the vacuum motor. 1 Remove the clip. 2 Remove the nuts. 3 Remove the vacuum motor. 10. Disconnect the vacuum lines and remove the vacuum motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7179 Air Door Actuator / Motor: Service and Repair Blend Door Motor REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel. 3. Disconnect the connector. 4. Remove the four screws. 5. Remove the electronic blend door actuator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Recirculating Air/Air Inlet Duct Air Duct: Service and Repair A/C Recirculating Air/Air Inlet Duct REMOVAL 1. Remove the instrument panel. 2. Remove the plenum chamber. 3. Remove the RH front wheel and tire. 4. Remove the bolts and reposition the fender apron. 5. Remove the bolt. 6. Remove the screws and the pin-type retainer and reposition the cowl top cover to access the duct nut. 7. Remove the nut. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Recirculating Air/Air Inlet Duct > Page 7184 8. Remove the nut and position the harness cover aside. 9. Remove the nut. 10. Remove the bolt. 11. Remove the wiring harness. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Recirculating Air/Air Inlet Duct > Page 7185 12. Disengage the connectors and remove the air recirculating duct. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Recirculating Air/Air Inlet Duct > Page 7186 Air Duct: Service and Repair Instrument Panel Ducts DISASSEMBLY 1. Remove the instrument panel. 2. Remove the screw and remove the bracket. 3. Disengage the in-car temperature sensor hose retainers. 4. Remove the screws. 5. Remove the RH panel duct. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Recirculating Air/Air Inlet Duct > Page 7187 6. Remove the screws and the RH demister nozzle. 7. Remove the screws and the LH demister nozzle. 8. Disengage the radio antenna. 9. Remove the screws retaining the LH panel duct to the defroster duct, but do not remove the duct. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Recirculating Air/Air Inlet Duct > Page 7188 10. Remove the screws and remove the defroster duct. 11. Remove the LH panel duct. ASSEMBLY 1. To assemble, reverse the disassembly procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Recirculating Air/Air Inlet Duct > Page 7189 Air Duct: Service and Repair Rear Seat Air Flow REMOVAL 1. Remove the seats. 2. Remove the carpet. 3. Remove the pin-type retainer on each side of the duct and remove the duct. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Recirculating Air/Air Inlet Duct > Page 7190 Air Duct: Service and Repair Removal and Installation REMOVAL 1. Remove the rear seat airflow duct. 2. Remove the steering column lower cover. 3. Remove the vacuum motor screws. 4. Remove the heater outlet floor duct. 1 Position the vacuum motor aside. 2 Remove the screws. 3 Remove the heater outlet floor duct. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Left and Center Air Register: Service and Repair Left and Center Radio Removal Tool Special Tool(S) REMOVAL 1. Use the Radio Removing Tool to remove the radio chassis. 2. Disconnect the antenna lead and the wire harness connectors. 3. Remove the 8 screws and remove the finish panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Left and Center > Page 7195 4. Disconnect the connector, each side of steering column. 5. Disconnect the headlight and dimmer switch wire harness connectors. 6. Disengage the four lock tabs and remove the register assemblies. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Left and Center > Page 7196 Air Register: Service and Repair Right REMOVAL 1. Remove the passenger side airbag. 2. Remove the screw and the RH instrument panel register. 3. Disengage the lock tabs and remove the register assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 7197 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Air Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Description and Operation Ambient Air Temperature Sensor: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Air Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Description and Operation > Page 7201 Ambient Air Temperature Sensor: Service and Repair REMOVAL 1. Remove the radiator upper sight shield. 2. Disconnect the wire harness connector. 3. Remove the A/C ambient air temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation Blower Motor: Description and Operation The A/C blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 7205 Blower Motor: Service and Repair REMOVAL 1. Disengage the wire harness connectors from the retainer. 2. Disconnect the wire harness connector. 3. Remove the hose. 4. Remove the screws and remove the blower motor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 7206 5. Remove the wheel from the blower motor. 1 Remove the push clip. 2 Remove the wheel from the blower motor. CAUTION: Prior to removing a wheel that is to be reused, clean any corrosion from the blower motor shaft to prevent damage to the wheel mounting shaft. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation Blower Motor Resistor: Description and Operation The heater blower motor switch resistor has the following features: - The assembly is located in the engine compartment on the evaporator housing toward the center of the vehicle. - Three resistor elements are mounted on the resistor board to provide four blower motor speeds. - Depending on the heater blower motor switch position, series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed. - An overheating protective device (thermal limiter) will open the resistor coil when the temperature reaches 121°C (250°F). interrupting the blower motor operation in all speeds except HI. - The thermal limiter cannot be reset and is not serviceable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This model is not equipped with a cabin air filter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > In-Car Temperature Sensor <--> [Cabin Temperature Sensor / Switch] > Component Information > Description and Operation In-Car Temperature Sensor: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the A/C evaporator housing and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow takes air from the A/C evaporator housing air stream to create a suction in the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > In-Car Temperature Sensor <--> [Cabin Temperature Sensor / Switch] > Component Information > Description and Operation > Page 7216 In-Car Temperature Sensor: Service and Repair REMOVAL 1. Remove the finish panel. 2. Disconnect the connector. 3. Remove the screws and pull the control assembly away from the instrument panel. 4. Remove the screws and position the in-car temperature sensor to access the connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > In-Car Temperature Sensor <--> [Cabin Temperature Sensor / Switch] > Component Information > Description and Operation > Page 7217 5. Disconnect the connector. 6. Disconnect the hose and remove the in-car temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Clutch Air Gap and Runout Compressor Clutch: Specifications Clutch Air Gap and Runout MAGNETIC CLUTCH Air Gap Between Pulley and Hub ................................................................................................................. 0.35 mm - 0.85 mm (0.014 - 0.033 inch) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Clutch Air Gap and Runout > Page 7223 Compressor Clutch: Specifications Torque A/C Compressor Clutch Retaining Bolt ........................................................................................................................................ 11-14 N.m (98-123 Lb-In) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7224 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specifications. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Coil <--> [Compressor Clutch Coil] > Component Information > Service and Repair A/C Compressor Clutch Coil: Service and Repair Special Tool(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch hub spacer to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Coil <--> [Compressor Clutch Coil] > Component Information > Service and Repair > Page 7228 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the Field Coil Remover on the nose opening of the A/C compressor. 3 Install the Puller - Differential Bearing Cone Remover. 4 Remove the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Coil <--> [Compressor Clutch Coil] > Component Information > Service and Repair > Page 7229 2 Place the Field Coil Replacer on the A/C clutch field coil. Place the Coil Replacer on the Field Coil Replacer. 3 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Coil <--> [Compressor Clutch Coil] > Component Information > Service and Repair > Page 7230 7. Install the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Tighten the bolt. 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Coil <--> [Compressor Clutch Coil] > Component Information > Service and Repair > Page 7231 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair Compressor Shaft Seal: Service and Repair Special Tool(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. 2. Remove the shaft seal felt from the nose of the A/C compressor with the O-ring Remover. 3. Clean the compressor nose area. 4. Insert the tip of the Snap Ring Remover into one of the snap ring eyes. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 7235 5. Rotate the Snap Ring Remover to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 6. Pull the Snap Ring Remover up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. 7. Engage the Compressor Remover into the inside diameter of the shaft seal. 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 7236 9. Pull the seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. 2. Place the shaft seal on the Seal Protector. Lubricate the shaft seal and the Seal Protector with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 3. Position the shaft seal and the Seal Protector over the A/C compressor shaft. 4. Push the shaft seal onto the A/C compressor shaft with the Shaft Seal Installer until seated. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 7237 5. Install the shaft seal snap ring with the sharp edge facing up. 6. Carry out the A/C compressor external leak test. 7. Install the shaft seal felt. 8. Install the A/C clutch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 7238 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7242 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7243 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications Compressor Fitting HVAC: Specifications A/C Manifold And Tube Retaining Bolt ......................................................................................................................................... 18-24 N.m (14-17 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7247 Compressor Fitting HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Remove the A/C compressor to condenser discharge line nut. 4. Disconnect the A/C compressor to condenser discharge line from the A/C manifold and tube. 5. Disconnect the evaporator to compressor suction line from the A/C manifold and tube. 6. Loosen the bolt and remove the A/C manifold and tube. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7248 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. - Apply Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to the threads of the A/C manifold bolt. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Condenser Core Mounting Bolts ............................................................................................................................................... 8-11 N.m (71-97 Lb-In) Compressor To Condenser Tube Bracket Retaining Nut ................................................................................................................ 17-23 N.m (13-16 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7252 Condenser HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The A/C condenser core has the following characteristics: - It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator. - It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7253 Condenser HVAC: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. 2. Disconnect the suspect A/C evaporator core from the air conditioning system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R12-/R134-a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R134-a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7254 Condenser HVAC: Service and Repair REMOVAL NOTE: - If an A/C condenser core leak is suspected, the A/C condenser core must be leak tested before it is removed from the vehicle. - Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. 1. Recover the refrigerant. 2. Remove the battery. 3. Remove the radiator upper sight shield. 4. Disconnect the condenser to evaporator tube from the A/C condenser core. 5. Disconnect the A/C compressor to condenser discharge line from the A/C condenser core. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7255 6. Remove the bolts and remove the radiator supports. 7. Remove the two bolts. 8. Tilt the radiator back and lift out the A/C condenser core. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7256 1. To install, reverse the removal procedure. - Service the new A/C condenser core with the correct amount of PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation Control Assembly: Description and Operation The climate control assembly has three system controls: - The A/C heater function selector switch combines a vacuum selector valve with two electrical switches to supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control circuit. - Temperature selection is accomplished with a potentiometer connected to the electric blend door. Movement of the control knob from COOL (Blue) to WARM (Red) causes a corresponding movement on the air temperature blend door and determines the temperature that the system will maintain. - The blower motor switch controls blower motor speed by adding or bypassing resistors in the heater blower motor switch resitor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches Control Assembly: Service and Repair Climate Control Switches REMOVAL 1. Remove the control assembly. 2. Remove the function selector. 1 Depress the snap tabs. 2 Remove the function selector. NOTE: The knob will drop off as the function selector is removed. 3. Remove the temperature blend control switch. 1 Remove the screw. 2 Rotate and pull the temperature blend control switch. NOTE: The knob will drop off as the temperature blend control switch is removed. 4. Remove the blower motor switch. 1 Depress the snap tabs. 2 Remove the blower motor switch. NOTE: The knob will drop off as the blower motor switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches > Page 7262 Control Assembly: Service and Repair With Manual A/C REMOVAL 1. Remove the finish panel. 2. Disconnect the connector. 3. Remove the climate control head. 1 Remove the screws. 2 Remove the climate control head. 4. Disconnect the climate control head. - Disconnect the electrical connectors. - Disconnect the vacuum line connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches > Page 7263 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 7268 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 7269 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 7272 Control Module HVAC: Diagrams Electronic Climate Control Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control Control Module HVAC: Description and Operation Blower Motor Speed Control The A/C blower motor speed control is located on the A/C evaporator housing, in the engine compartment. - The function of the A/C blower motor speed control is to convert low power signals from the electronic automatic temperature control module to a high current, variable ground feed for the blower motor. - Blower motor speed is infinitely variable and is controlled by the electronic automatic temperature control module software. - A delay function provides a gradual increase or decrease in blower motor speed under all conditions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control > Page 7275 Control Module HVAC: Description and Operation Electronic Climate Control Module The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: - a blower speed override control for manual input - a vacuum fluorescent display for displaying set temperature, ambient temperature, function and Diagnostic Trouble Codes (DTCs) - an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes (DTCs). These DTCs direct the technician to the inoperative component. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control Control Module HVAC: Service and Repair Blower Motor Speed Control REMOVAL 1. Disconnect the wire harness connector. 2. Drain the cooling system below the heater hoses. 3. Disconnect the heater hose. 4. Remove the screws and remove the blower motor speed control. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 7278 Control Module HVAC: Service and Repair Electronic Climate Control Module REMOVAL 1. Remove the finish panel. 2. Disconnect the connector. 3. Remove the screws and pull the Electronic Automatic Temperature Control (EATC) module from the instrument panel. 4. Remove the EATC module. - Remove the nuts and the vacuum harness. - Disconnect the wire harness connectors and remove the EATC module. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 7279 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications Coupler HVAC: Specifications Peanut Fitting Nut ................................................................................................................................ ............................................... 7-9 N.m (62-79 Lb-In) Peanut Fitting Retaining Nut ............................ ................................................................................................................................... 7-9 N.m (62-79 Lb-In) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Peanut Fitting Coupler HVAC: Description and Operation Peanut Fitting The A/C condenser core uses the peanut-shaped refrigerant fittings instead of spring lock couplings. - The male and female blocks of the peanut fitting are retained with a nut. - An O-ring seal is installed around the tube on the male block. - The female block is welded to the tube and is not adjustable. - Support the female fitting with a wrench to prevent twisting of the tubes. - The male block will pivot around the tube to allow for alignment with the female block during assembly. - When properly assembled the male and female fittings should be flush. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Peanut Fitting > Page 7285 Coupler HVAC: Description and Operation Spring Lock Coupling Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. - When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. - The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. - Three O-ring seals are used to seal between the two halves of the A/C condenser core couplings, all other couplings have two O-ring seals. - These O-ring seals are green in color and are made of special material. - Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. - A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. - The indicator ring may also be used during service operations to indicate connection of the coupling. - An A/C tube lock coupling clip may be used to secure the coupling but is not required. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting Coupler HVAC: Service and Repair Peanut Fitting DISCONNECT 1. Remove the nut from the peanut fitting. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. 2. Pull the peanut fitting apart. 3. Remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove resulting in refrigerant leaks. CONNECT 1. Clean all dirt or foreign material from the fittings. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7288 2. Install the O-ring seal. - Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new green O-rings seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 4. Assemble the male and female fittings together. NOTE: When correctly assembled the male and female fittings should be flush. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7289 Coupler HVAC: Service and Repair Spring Lock Coupling Spring Lock Coupling Disconnect Tool Set Special Tool(S) DISCONNECT 1. Disconnect the A/C tube lock coupling clip. 2. Fit the spring lock coupling disconnect tool to the spring lock coupling. 3. Push the tool into the cage opening to release the female fitting from the A/C tube look coupling spring. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7290 4. Pull the spring lock coupling fittings apart. 5. Remove the O-ring seals with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. 6. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. CLEANING 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. Coupling Size Pad Size 3/8 inch 25 x 50 mm (1 x 2 inch) 1/2 inch 25 x 50 mm (1 x 2 inch) 5/8 inch 25 x 76 mm (1 x 3 inch) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7291 3/4 inch 25 x 102 mm (1 x 4 inch) 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 5. Roll the pad on the tool and install it in a variable speed drill motor. 6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free of scratches or foreign material. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component. 9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. - Loop the string around the grooves and pull the string back and forth. 10. Remove any foreign material from the grooves with a lint-free cloth. CONNECT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7292 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 3. Install the O-ring seals. - Lubricate the O-ring seals with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may resuit in intermittent leakage during vehicle operation. 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. 5. Install the A/C tube lock coupling clip. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair Evaporator Case: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Drain the radiator so that the coolant level is below the heater core. 4. Raise the vehicle. 5. Remove the RH front wheel and tire. 6. Remove the screws from the RH fender apron and remove the fender apron. 7. Remove the nuts. 8. Lower the vehicle. 9. Remove the blower motor switch resistor. 10. Disconnect the connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 7296 11. Disconnect the evaporator to compressor suction line from the suction accumulator drier. 12. Disconnect the condenser to evaporator tube from the A/C evaporator core inlet tube. 13. Remove the nuts and position the purge valve and bracket away from the evaporator core housing. 14. Remove the heater hoses from the heater core. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 7297 15. Disengage the connectors from the bracket. 16. Disconnect the connector. 17. Remove the nut and reposition the wire harness away from the evaporator housing. 18. Disengage the harness from the bracket. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 7298 19. Remove the pin-type retainer and clip and remove the instrument panel lower insulator. 20. Fold back the carpet and remove the screw. 21. Inside the vehicle, remove the screw. 22. Remove the nuts (engine side). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 7299 23. Remove the in-car temperature sensor hose and elbow from the evaporator housing (if equipped). 24. Remove the evaporator housing. INSTALLATION 1. Position the evaporator core housing on the dash panel. 2. Install the in car temperature sensor hose. 3. Install the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 7300 4. Install the screw. 5. Install the screw. 6. Install the RH lower instrument panel insulator. 7. Raise the vehicle. 8. Install the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 7301 9. Position fender apron and install the bolts. 10. Install the front wheel and tire. 11. Lower the vehicle. 12. Connect the connector. 13. Install the connectors. 14. Install the wire harness push connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 7302 15. Position harness and install the nut. 16. Install the nuts. 17. Install the heater hoses. - Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 18. Connect the evaporator compressor suction line to the suction accumulator/drier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 7303 19. Connect the condenser to evaporator tube. 20. Connect the connector. 21. Install the blower motor switch resistor. 22. Connect the battery ground cable. 23. Fill the cooling system. 24. Evacuate and recharge the refrigerant system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation Evaporator Core: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. - A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin sections. - The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C evaporator core. - Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. - This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7307 Evaporator Core: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. 2. Disconnect the suspect A/C evaporator core from the air conditioning system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R12-/R134-a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R134-a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7308 Evaporator Core: Service and Repair REMOVAL NOTE: - Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. - If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Remove the A/C evaporator core housing. 4. Remove the six screws. 5. Carefully cut the seal in two places and separate the two halves of the evaporator housing. 6. Disconnect the suction accumulator/drier from the evaporator core outlet tube. CAUTION: To prevent damage to the fitting and tube, always use a backup wrench when removing the suction accumulator/drier. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7309 7. Remove the screws and remove the suction accumulator/drier. 8. Remove the A/C evaporator core. INSTALLATION 1. To install, reverse the removal procedure. - Service the new A/C evaporator core with the correct amount of PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component Information > Specifications Orifice Tube: Specifications Color Code .......................................................................................................................................... ........................................................................ Orange Orifice Diameter ............................................. ........................................................................................................................................ 1.46 mm (0.0575 in) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component Information > Specifications > Page 7313 Orifice Tube: Description and Operation NOTE: A new A/C evaporator core orifice should be installed whenever a new A/C compressor is installed. The A/C evaporator core orifice has the following characteristics: - It is located in the A/C evaporator core inlet tube. - It has filter screens located on the inlet and outlet ends of the tube body. - The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. - O-ring seals on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from bypassing the A/C evaporator core orifice. - Adjustment or service cannot be made to the A/C evaporator core orifice assembly. It must be installed as a unit. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component Information > Specifications > Page 7314 Orifice Tube: Service and Repair Special Tool(S) REMOVAL 1. Remove the condenser to evaporator tube. - For a fixed orifice tube, perform Steps 2 and 3. - For a broken orifice tube, perform Steps 4 and 5. 2. Engage the Fixed Orifice Tube Tool to the A/C evaporator core orifice. 3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C evaporator core orifice. 4. Screw the end of the Broken Orifice Extractor into the broken A/C evaporator core orifice. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component Information > Specifications > Page 7315 5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator core orifice. INSTALLATION 1. Lubricate and install the O-ring seals on the A/C evaporator core orifice. - Use PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Tool. 3. Insert the A/C evaporator core orifice into the tube end until seated. 4. Remove the Fixed Orifice Tube Tool. 5. Install the condenser to evaporator tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component Information > Specifications > Page 7316 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7325 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7326 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7332 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7333 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: All Technical Service Bulletins Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 7339 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 7345 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7346 Heater Core: Specifications Rubber Suspension Insulator Lube E25Y-19553-A .................................................................................................................................... ESF-M99B112-A Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7347 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7348 Heater Core: Testing and Inspection WARNING: Carbon monoxide is colorless, odorless and dangerous. If it is necessary to operate the engine with the vehicle in a closed area such as a garage, always use an exhaust collector to vent the exhaust gases outside the closed area. Failure to follow these instructions may result in personal injury. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and a new heater core was not required. 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. 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: The heater core inlet hose will become too hot to handle if the system is working correctly. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: - the heater core may have an air pocket. - the heater core may be plugged. - the thermostat may not be working correctly. Heater Core-Pressure Test Use the Radiator/Heater Core Pressure Tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7349 Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core Heater Core: Service and Repair Back Flushing-Heater Core Special Tools 1. WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. when you are sure all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. Once pressure is released, remove the pressure relief cap. 2. Partially drain the cooling system. 3. NOTE: Refer to the cooling system Flush-All Operating Instructions for particular vehicle hook-up. Use cooling system Flush-All, Flush Kit Hardware Package and Drain Kit to backflush the heater core. Use Ford Premium Cooling System Flush F1AZ-19A503-A meeting Ford specification ESR-M14P7A for vehicles filled with Premium Engine Coolant E2FZ-19549-AA or equivalent meeting Ford specification ESE-M97B44-A (green color). Use warm water for vehicles filled with Extended Life Engine Coolant F6AZ-19544-AA or equivalent meeting Ford specification WSS-M97B44-D or DEX-COOL (orange color). 4. Fill the cooling system. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 7352 Heater Core: Service and Repair Removal and Installation REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Remove the plenum chamber. See: Heater Air Plenum Chamber/Service and Repair 2. Remove the screws and the heater core cover. 3. Carefully cut the seal above the heater core inlet and outlet tubes and remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 7353 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] > Component Information > Service and Repair Heater Air Plenum Chamber: Service and Repair REMOVAL 1. Remove the rear seat airflow duct. 2. Remove the instrument panel. 3. Drain the coolant from the radiator so the coolant level is below the heater core. 4. Disconnect the heater water hoses. 5. Inside the vehicle, remove the nut. 6. Disconnect the vacuum hoses. NOTE: Mark the locations of the vacuum hoses. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] > Component Information > Service and Repair > Page 7357 7. Disconnect the vacuum hose. 8. Remove the pin-type retainers and remove the vacuum harness. 9. Disconnect the connector. 10. Remove the nuts. 11. Disconnect the connectors. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] > Component Information > Service and Repair > Page 7358 12. Remove the in-car temperature sensor hose (if equipped). 13. Remove the plenum chamber. INSTALLATION 1. Position the plenum chamber on the dash panel. 2. Install the nuts. 3. Install the nut. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] > Component Information > Service and Repair > Page 7359 4. Install the in-car temperature sensor hose (if equipped). 5. Install the connector. 6. Install the vacuum harness. 7. Connect the vacuum hose. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] > Component Information > Service and Repair > Page 7360 8. Connect the vacuum hoses. 9. Install the heater water hoses. - Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 10. Refill the cooling system. 11. Install the heater outlet floor duct. 12. Install the instrument panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7369 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7370 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7376 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7377 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 7378 Heater Hose: Service and Repair REMOVAL 1. Drain the radiator. 2. Remove the heater hoses from the heater core. 3. Remove the heater hoses from the engine. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Mechanical Specifications High Pressure Safety Valve HVAC: Mechanical Specifications A/C Pressure Relief Valve .............................................................................................................................................................. 5-14 N.m (45-123 Lb-In) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Mechanical Specifications > Page 7383 High Pressure Safety Valve HVAC: Pressure, Vacuum and Temperature Specifications A/C High Pressure Safety Valve Open .................................................................................................................................................... ..................................... 3103 kPa (450 psi) maximum Compressor Relief Valve Open .................................................................................................................................................... ..................................... 3103 kPa (450 psi) maximum Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > A/C High Pressure Safety Valve High Pressure Safety Valve HVAC: Description and Operation A/C High Pressure Safety Valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups (3,103 kPa and above). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > A/C High Pressure Safety Valve > Page 7386 High Pressure Safety Valve HVAC: Description and Operation Compressor Relief Valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups (3,103 kPa and above). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > A/C High Pressure Safety Valve High Pressure Safety Valve HVAC: Service and Repair A/C High Pressure Safety Valve REMOVAL 1. Recover the refrigerant. 2. Remove the A/C compressor pressure relief valve. INSTALLATION 1. To install, reverse removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > A/C High Pressure Safety Valve > Page 7389 High Pressure Safety Valve HVAC: Service and Repair Compressor Relief Valve REMOVAL 1. Recover the refrigerant. 2. Remove the A/C compressor pressure relief valve. INSTALLATION 1. To install, reverse removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation REFRIGERANT LINES NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C compressor to condenser discharge line contains high pressure refrigerant gas. It has the following features: an integral non-serviceable muffler - a fitting used to mount the A/C pressure cut-off switch. (A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system.) - a fitting used to mount a serviceable high-pressure A/C charge port valve The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a port to mount the A/C compressor pressure relief valve. The accumulator to compressor tube has a fitting used to mount the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Disconnect the A/C pressure cut-off switch wire harness connector. 4. Remove the A/C pressure cut-off switch. 5. Remove the A/C compressor to condenser discharge line nut. 6. Disconnect the A/C compressor to condenser discharge line from the A/C manifold and tube. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 7395 7. Disconnect the A/C compressor to condenser discharge line from the A/C condenser core and remove the A/C compressor to condenser discharge line. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 7396 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Condenser To Evaporator Line REMOVAL 1. Recover the refrigerant. 2. Disconnect the condenser to evaporator tube from the A/C evaporator core. 3. Disconnect the condenser to evaporator tube from the A/C condenser core and remove the condenser to evaporator tube. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Evaporator to Compressor Suction Line REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 7397 3. Disconnect the A/C cycling switch wire harness connector. 4. Remove the A/C cycling switch. 5. Disconnect the evaporator to compressor suction line from the suction accumulator/drier. 6. Disconnect and remove the evaporator to compressor suction line from the A/C manifold and tube assembly. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Page 7398 Spring Lock Coupling Disconnect Tool Set Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The suction accumulator/drier is mounted to the right of the vehicle centerline. The inlet tube of the suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet tube of the suction accumulator/drier attaches to the evaporator to compressor suction line. After entering the inlet of the suction accumulator/drier, heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. - As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. - A fitting located on the side of the suction accumulator/drier is used to mount a serviceable low-pressure A/C charge port valve. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7406 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7407 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7408 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7409 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ........................................................... 1.08 kg (38 oz) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7412 Refrigerant: Fluid Type Specifications Refrigerant............................................................................................................................................ ........................................................................R134a Ford Part Number ................................................................................................................................ ..................................................................... YN-19 Ford Specification ................................................................................................................................ ................................................... WSH-M17B19-A Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Oil Capacity ......................................................................................................................................... ........................................................... 222 ml (7.5 oz) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7417 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil...................................................................................................................................... ...Polyalkylene Glycol (PAG) Oil (R-134a Systems) Ford Part Number ........................................................................................................................................................... F7AZ-19589-AD (MC-YN-12C) Ford Specification ................................................................................................................................ .................................................. WSH-M1C231-B Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Pressure Cut-off Switch ..................................................................................................................................................... 6.8-13.6 N.m (61-120 Lb-In) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 7422 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Close ................................................................................................................................................... .................................... 276-324 kPa (40-47 psi) Open ....................................................................... ................................................................................................................ 152-193 kPa (22-28 psi) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the A/C compressor to condenser discharge line. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 7425 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the suction accumulator/driver. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction or low side pressure to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the wire harness connector. 2. Remove the A/C cycling switch. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 7428 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the wire harness connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7433 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7434 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 7439 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 7440 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 7443 Control Module HVAC: Diagrams Electronic Climate Control Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control Control Module HVAC: Description and Operation Blower Motor Speed Control The A/C blower motor speed control is located on the A/C evaporator housing, in the engine compartment. - The function of the A/C blower motor speed control is to convert low power signals from the electronic automatic temperature control module to a high current, variable ground feed for the blower motor. - Blower motor speed is infinitely variable and is controlled by the electronic automatic temperature control module software. - A delay function provides a gradual increase or decrease in blower motor speed under all conditions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control > Page 7446 Control Module HVAC: Description and Operation Electronic Climate Control Module The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: - a blower speed override control for manual input - a vacuum fluorescent display for displaying set temperature, ambient temperature, function and Diagnostic Trouble Codes (DTCs) - an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes (DTCs). These DTCs direct the technician to the inoperative component. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control Control Module HVAC: Service and Repair Blower Motor Speed Control REMOVAL 1. Disconnect the wire harness connector. 2. Drain the cooling system below the heater hoses. 3. Disconnect the heater hose. 4. Remove the screws and remove the blower motor speed control. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 7449 Control Module HVAC: Service and Repair Electronic Climate Control Module REMOVAL 1. Remove the finish panel. 2. Disconnect the connector. 3. Remove the screws and pull the Electronic Automatic Temperature Control (EATC) module from the instrument panel. 4. Remove the EATC module. - Remove the nuts and the vacuum harness. - Disconnect the wire harness connectors and remove the EATC module. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 7450 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Air Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Description and Operation Ambient Air Temperature Sensor: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Air Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Description and Operation > Page 7455 Ambient Air Temperature Sensor: Service and Repair REMOVAL 1. Remove the radiator upper sight shield. 2. Disconnect the wire harness connector. 3. Remove the A/C ambient air temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > In-Car Temperature Sensor <--> [Cabin Temperature Sensor / Switch] > Component Information > Description and Operation In-Car Temperature Sensor: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the A/C evaporator housing and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow takes air from the A/C evaporator housing air stream to create a suction in the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > In-Car Temperature Sensor <--> [Cabin Temperature Sensor / Switch] > Component Information > Description and Operation > Page 7459 In-Car Temperature Sensor: Service and Repair REMOVAL 1. Remove the finish panel. 2. Disconnect the connector. 3. Remove the screws and pull the control assembly away from the instrument panel. 4. Remove the screws and position the in-car temperature sensor to access the connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > In-Car Temperature Sensor <--> [Cabin Temperature Sensor / Switch] > Component Information > Description and Operation > Page 7460 5. Disconnect the connector. 6. Disconnect the hose and remove the in-car temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Pressure Cut-off Switch ..................................................................................................................................................... 6.8-13.6 N.m (61-120 Lb-In) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 7465 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Close ................................................................................................................................................... .................................... 276-324 kPa (40-47 psi) Open ....................................................................... ................................................................................................................ 152-193 kPa (22-28 psi) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the A/C compressor to condenser discharge line. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 7468 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the suction accumulator/driver. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction or low side pressure to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the wire harness connector. 2. Remove the A/C cycling switch. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 7471 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the wire harness connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top RH side of the instrument panel above the glove compartment. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Page 7475 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the wire harness connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation Service Gauge Port Values The high-pressure service gauge port valve is located on the front A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator/drier. The fitting is an integral part of the refrigeration line or component. - Special couplings are required for both the high side and low side service gauge ports. - A new Schrader-type valve core can be installed if the seal leaks. - Always install the A/C charging valve cap on the service gauge port valves afier repairing the refrigerant system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top RH side of the instrument panel above the glove compartment. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Page 7482 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the wire harness connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair Vacuum Pump Kit Special Tool(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch) longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: Read the warning information on the product label to prevent possible personal injury. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8 inch repair vacuum hose section. 6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. - Use the Vacuum Tester or equivalent. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair > Page 7486 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Remove the relay module. 2. Disconnect the vacuum hose. 3. Raise the vehicle. 4. From inside the LH wheel well, remove the nuts. 5. Remove the vacuum reservoir tank. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedures 1. Disconnect the battery ground cable and wait at least one minute. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedures 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Install the passenger air bag module. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 7497 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the vehicle battery connected? Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications Air Bag: Specifications Air bag Electronic Crash Sensor (ECS) module bolts .................................................................................................................................. 12 Nm (9 Lb-Ft) Driver air bag module bolts .................................................................................................................. ........................................................ 12 Nm (9 Lb-Ft) Passenger air bag module bolts ....................... .............................................................................................................................................. 9 Nm (80 Lb-In) Air bag sensor bolts .................................................................................................................. .................................................................... 12 Nm (9 Lb-Ft) Aft steering column nuts ....................... ...................................................................................................................................................... 15 Nm (11 Lb-Ft) Forwarded Steering column nuts ................................................................................. .............................................................................. 15 Nm (11 Lb-Ft) Crash sensor grounding screw weld nut repair screw (8 mm) ....................................................................................................................... 12 Nm (9 Lb-Ft) Grounding screw (6 mm) ..................................................................................................................... ......................................................... 12 Nm (9 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module Air Bag: Locations Driver Air Bag Module The driver air bag module: - is replaced as an assembly. - is mounted in the center of the steering wheel. Air Bag Sliding Contact The air bag sliding contact: is mounted on the steering column, behind the steering wheel. - continuously transfers electrical signals from the driver air bag module to the air bag Electronic Crash Sensor (ECS) module. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 7503 Air Bag: Locations Passenger Airbag The passenger air bag module: - is replaced as an assembly. - is mounted in the RH side of the instrument panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 7504 Air Bag: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be replaced, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module Air Bag: Description and Operation Driver Air Bag Module The driver air bag module: - is replaced as an assembly. - is mounted in the center of the steering wheel. Air Bag Sliding Contact The air bag sliding contact: is mounted on the steering column, behind the steering wheel. - continuously transfers electrical signals from the driver air bag module to the air bag Electronic Crash Sensor (ECS) module. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module > Page 7507 Air Bag: Description and Operation Passenger Air Bag Module The passenger air bag module: - is replaced as an assembly. - is mounted in the RH side of the instrument panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module Air Bag: Service and Repair Driver Air Bag Module REMOVAL WARNING: - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be replaced, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the two driver air bag module retaining bolts. 3. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch electrical connector. 3. Remove the driver air bag module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7510 1. Follow the removal procedure in reverse order. WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7511 Air Bag: Service and Repair General Procedures Air Bag Disposal-Deployed Air Bag 1. Dispose of the deployed air bag modules in the same manner as any other part to be scrapped. WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Air Bag Disposal-Undeployed Air Bag, Inoperative WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 1 Remove the inoperative driver air bag module or passenger air bag module. NOTE: All inoperative air bag modules have been placed on the Mandatory Return List. All discolored or damaged air bag modules should treated the same as any inoperative live air bag being returned. 2 When installing a new driver air bag module, record the necessary information and return the inoperative driver air bag module to Ford Motor Company. NOTE: When installing a new air bag module, a prepaid return postcard is provided with the replacement air bag module. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. 3. When installing a new passenger air bag module, record the necessary information and return the inoperative passenger air bag module to Ford Motor Company. Air Bag Disposal-Undeployed Air Bag, Scrapped Vehicle Remote Deployment WARNING: - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the air bag is deployed, hearing protection is required. - Do not place the driver or passenger air bag module with the trim cover or deployment door facing down, as the forces of the deploying air bag can cause it to ricochet and cause personal injury. NOTE: The passenger air bag module is shown. The driver air bag module is similar. 1. Remove the passenger air bag module. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7512 2. Cut the two connector wires on the passenger air bag module, and strip 25 mm (1 in) of insulation from the ends of the wires. 3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and connect one end of each wire to each of the wires on the passenger air bag module. 4. Place the passenger air bag module on a flat surface with the deployment door facing upward in an open outdoor area. 5. Remain at least 6.1 meters (20 feet) away from the passenger air bag module. 6. Deploy the air bag by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. Allow at least ten minutes before approaching the deployed air bag to allow for cooling. 8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped. Wiring Repair 1. Inspect the Supplemental Restraint System (SRS) wiring and the wiring harness for any damage that may have occurred as a result of the accident. Inspect and repair or install new, as required, any damaged: insulation. - terminal. - connectors. - splices. 2. Splice damaged wires using the specified butt-splice connector or equivalent. - For splices required in adjacent wiring, stagger the splices 51 mm (2.04 in) apart from each other. - Use waterproof butt-splice type connectors. - Use the correct size heat shrink nylon tube to prevent water, salt, condensation, and heat from affecting the wiring repair. Make sure the tube extends 25 mm (1 in) each side of the repair. - Use a splice connector that is lined with a sealer that melts when heated with a heat gun and flows from the tubing, sealing the splice. - Use the correct gauge connector for the wire being repaired. - Use connectors that are transparent to allow inspection of the finished splice. Connector identification Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7513 Description ........................................................................................................................................... ............................................................ Specification Butt connector gauge 18-22 ...................................................................................................................................................... Red, Class C E6FZ-14488-A Butt connector gauge 14-16 ..................................................................................................................................................... Blue, Class C E6FZ-14488-B Butt connector gauge 10-12 ................................................................................................................................................. Yellow, Class C E6FZ-14488-C "J" Nut, Electronic Crash Sensor (ECS) and Front Crash Sensor WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: - There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. - If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair-Missing Weld Nut, Electronic Crash Sensor (ECS) and Front Crash Sensor. - The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part numbers N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N80085-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Missing Weld Nut, Electronic Crash Sensor & Front Crash Sensor WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: - There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. - If two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair "J" Nut, Electronic Crash Sensor (ECS) and Front Crash Sensor. Weld nuts must be installed as outlined in this procedure. - Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut. 2. Obtain a 6 mm (0.24 in) grounding screw. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7514 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Stripped Weld Nut, Electronic Crash Sensor & Front Crash Sensor WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Obtain an 8 mm (0.32 in) grounding screw. 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7515 Air Bag: Service and Repair Passenger Air Bag Module REMOVAL WARNING: - If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS) module. - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment which can result in personal injury. - Air bag modules with discolored or damaged deployment doors must be installed new, not repainted. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Open the glove compartment and disconnect the glove compartment isolator. 3. Push in on the two glove compartment door tabs and position downward. 4. Separate the trim panel by pulling straight out to release the retaining clips. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7516 5. Remove the trim panel. 1 Disconnect the clock. 2 Remove the trim panel. 6. Disconnect the passenger air bag module. 1 Disconnect the passenger air bag module electrical connector. 2 Remove the passenger air bag module retaining bolts. 7. Remove the passenger side air bag module. 1 Remove the two retaining screws. 2 Placing one hand in the glove box opening, push the passenger air bag out from the instrument panel and remove it. INSTALLATION WARNING: - If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS) module. - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment which can result in personal injury. NOTE: - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighten the retaining bolts to specification. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7517 1. Follow the removal procedure in reverse order. - Make sure the retaining clips on the back of the air bag module are fully seated in the slots in the substrate. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7518 Air Bag: Service and Repair Removal and Installation Driver's Side REMOVAL WARNING: - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be replaced, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the two driver air bag module retaining bolts. 3. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7519 3. Remove the driver air bag module. INSTALLATION 1. Follow the removal procedure in reverse order. WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Passenger's Side REMOVAL WARNING: - If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS) module. - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment which can result in personal injury. - Air bag modules with discolored or damaged deployment doors must be installed new, not repainted. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Open the glove compartment and disconnect the glove compartment isolator. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7520 3. Push in on the two glove compartment door tabs and position downward. 4. Separate the trim panel by pulling straight out to release the retaining clips. 5. Remove the trim panel. 1 Disconnect the clock. 2 Remove the trim panel. 6. Disconnect the passenger air bag module. 1 Disconnect the passenger air bag module electrical connector. 2 Remove the passenger air bag module retaining bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7521 7. Remove the passenger side air bag module. 1 Remove the two retaining screws. 2 Placing one hand in the glove box opening, push the passenger air bag out from the instrument panel and remove it. INSTALLATION WARNING: - If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS) module. - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment which can result in personal injury. NOTE: - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighten the retaining bolts to specification. 1. Follow the removal procedure in reverse order. - Make sure the retaining clips on the back of the air bag module are fully seated in the slots in the substrate. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Air bag Electronic Crash Sensor (ECS) module bolts .................................................................................................................................. 12 Nm (9 Lb-Ft) Driver air bag module bolts .................................................................................................................. ........................................................ 12 Nm (9 Lb-Ft) Passenger air bag module bolts ....................... .............................................................................................................................................. 9 Nm (80 Lb-In) Air bag sensor bolts .................................................................................................................. .................................................................... 12 Nm (9 Lb-Ft) Aft steering column nuts ....................... ...................................................................................................................................................... 15 Nm (11 Lb-Ft) Forwarded Steering column nuts ................................................................................. .............................................................................. 15 Nm (11 Lb-Ft) Crash sensor grounding screw weld nut repair screw (8 mm) ....................................................................................................................... 12 Nm (9 Lb-Ft) Grounding screw (6 mm) ..................................................................................................................... ......................................................... 12 Nm (9 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7525 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7526 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7527 Air Bag Control Module: Service Precautions WARNING: - The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have deployed. In addition, make sure the area of the (ECS) mounting is restored to its original condition. - If installing a new air bag module, always install a new air bag electronic crash sensor (ECS) module. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7528 Air Bag Control Module: Description and Operation The air bag Electronic Crash Sensor (ECS) module performs the following functions: - signals the inflators to deploy the air bags in the event of a deployable crash. - monitors the air bag Supplemental Restraint System (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). - signals the Lighting Control Module (LCM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the ECS and is not serviced separately. The ECS monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the ECS will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will flash the two-digit LFC. The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The ECS will also communicate the current and historical DTCs the DLC, using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system detects a fault condition, the ECS will signal the LCM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After the fault has been corrected, the next highest priority fault will be displayed. The ECS includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors close. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7529 Air Bag Control Module: Service and Repair REMOVAL WARNING: - The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have deployed. In addition, make sure the area of the (ECS) mounting is restored to its original condition. - If installing a new air bag module, always install a new air bag electronic crash sensor (ECS) module. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the RH sill plate. 3. Position the carpet out of the way. 4. Remove the ECS. 1 Disconnect the ECS electrical connector locking clip. 2 Disconnect the ECS electrical connector. 3 Remove the three retaining screws. 4 Remove the ECS module and bracket. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7530 1. Follow the removal procedure in reverse order. WARNING: The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have deployed. In addition, make sure the area of the (ECS) mounting is restored to its original condition. - If installing a new air bag module, always install a new air bag electronic crash sensor (ECS) module. - The tightening torque of the air bag electronic crash sensor (ECS) module bracket retaining screws is critical for correct system operation. NOTE: Make sure to tighten the retaining bolts to specification. - A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions Clockspring Assembly / Spiral Cable: Service Precautions WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE REPLACED, NOT REPAINTED. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF SO EQUIPPED). NOTE: Repair of the air-bag sliding contact (clock-spring) is made by REPLACEMENT only. If a part is replaced and the new part does not correct the condition, install the original part. Perform the diagnostic procedure again. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7534 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL WARNING: - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the driver air bag module. 3. Remove the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 4. Apply two strips of masking tape across the air bag sliding contact to prevent accidental rotation when the air bag sliding contact is removed. 5. Place the steering Column in the full down tilt position, then remove the tilt wheel handle and shank. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7535 6. Remove the lower steering column cover. 1 Remove the two bolts. 2 Position the parking brake release aside. 3 Remove the lower steering column cover. 7. Remove the lower steering column reinforcement. 1 Remove the five bolts. 2 Remove the lower steering column reinforcement. 8. Remove the lower steering column shroud. 1 Remove the four screws. 2 Remove the lower steering column shroud. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7536 9. Remove the ignition switch lock cylinder. 1 Position the ignition switch lock cylinder to the RUN position. 2 Using a suitable tool, push upward on the cylinder release tab while pulling the ignition switch lock cylinder outward. 10. Remove the instrument panel lower insulator. 11. Loosen the forward steering column mounting nuts. 12. Disconnect the transmission range indicator cable. 13. Loosen the aft steering column mounting nuts and allow the steering column to drop down enough for clearance to remove the upper steering column shroud. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7537 14. Remove the upper steering column shroud. 15. Remove the Passive Anti-theft System (PATS) transmitter. 1 Remove the PATS transmitter retaining screw. 2 Remove the PATS transmitter. 16. Remove the key-in-ignition warning indicator switch. 17. Disconnect the air bag sliding contact electrical connectors. 1 Cut and remove the tie strap. 2 Separate the wires from the wiring harness retainer. 3 Remove the sliding contact electrical connectors from the wire connector bracket, then disconnect the connectors. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7538 18. Remove the air bag sliding contact. 1. Pry the air bag sliding contact retaining clips loose. 2. Remove the air bag sliding contact. INSTALLATION WARNING: - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position and install the air bag sliding contact. 1 Install the air bag sliding contact on the steering column. 2 Make sure the retaining clips are engaged. 2. Connect the air bag sliding contact electrical connectors. 1 Connect the air bag sliding contact electrical connectors and install into the wire connector bracket. 2 Install the wires into the wiring harness retainer. 3 Install a new tie strap. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7539 3. Install the key-in-ignition warning indicator switch. 4. Install the passive anti-theft system (PATS) transmitter. 1 Position the PATS transmitter. 2 Install the PATS transmitter retaining screw. 5. Install the upper steering column shroud. 6. Install the ignition switch lock cylinder. - Position the ignition switch lock cylinder to the RUN position. - Insert the ignition switch lock cylinder into the steering column. - Make sure the ignition switch lock cylinder is fully seated and aligned in the inter-locking washer before turning the key to the OFF position. - Make sure the ignition switch lock cylinder retaining pin is seated in the hole in the steering column. - Rotate the ignition switch lock cylinder through all positions to verify operation. 7. Position the steering column up and hand-tighten the forward steering column mounting nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7540 8. Connect the transmission range indicator cable. 9. Tighten the aft steering column mounting nuts. 10. Tighten the forward steering column mounting nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7541 11. Install the lower steering column shroud. 1 Position the lower steering column shroud. 2 Install the four retaining screws. 12. Install the lower steering column reinforcement. 1 Position the lower steering column reinforcement. 2 Install the five bolts. 13. Install the lower steering column cover. 1 Position the lower steering column cover. 2 Position the parking brake release. 3 Install the two bolts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7542 14. Install the tilt wheel handle and shank. 15. Remove the two strips of masking tape across the air bag sliding contact. 16. Install the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 17. Install the driver air bag module. 18. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air bag Electronic Crash Sensor (ECS) module bolts .................................................................................................................................. 12 Nm (9 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 7546 Impact Sensor: Service Precautions WARNING: - Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 7547 Impact Sensor: Service and Repair REMOVAL WARNING: - Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator upper sight shield. 3. Remove the air bag sensor. 1 Disconnect the air bag sensor electrical connector. 2 Remove the three screws. 3 Remove the air bag sensor. INSTALLATION 1. Follow the removal procedure in reverse order. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle shop manual to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 7548 auxiliary batteries and power supplies (if equipped). NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module Side Air Bag: Service and Repair Driver Side Air Bag Module REMOVAL WARNING: - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be replaced, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the two driver air bag module retaining bolts. 3. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch electrical connector. 3. Remove the driver air bag module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 7553 1. Follow the removal procedure in reverse order. WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 7554 Side Air Bag: Service and Repair Passenger Side Air Bag REMOVAL WARNING: - If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS) module. - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment which can result in personal injury. - Air bag modules with discolored or damaged deployment doors must be installed new, not repainted. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Open the glove compartment and disconnect the glove compartment isolator. 3. Push in on the two glove compartment door tabs and position downward. 4. Separate the trim panel by pulling straight out to release the retaining clips. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 7555 5. Remove the trim panel. 1 Disconnect the clock. 2 Remove the trim panel. 6. Disconnect the passenger air bag module. 1 Disconnect the passenger air bag module electrical connector. 2 Remove the passenger air bag module retaining bolts. 7. Remove the passenger side air bag module. 1 Remove the two retaining screws. 2 Placing one hand in the glove box opening, push the passenger air bag out from the instrument panel and remove it. INSTALLATION WARNING: - If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS) module. - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment which can result in personal injury. NOTE: - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighten the retaining bolts to specification. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 7556 1. Follow the removal procedure in reverse order. - Make sure the retaining clips on the back of the air bag module are fully seated in the slots in the substrate. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation The air bag warning indicator is controlled by the air bag Electronic Crash Sensor (ECS). When starting the vehicle, the air bag warning indicator illuminates and remains lit for six seconds. The indicator only illuminates after starting the vehicle if a Supplemental Restraint System (SRS) malfunction is detected. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Page 7560 Malfunction Lamp / Indicator: Testing and Inspection For testing procedures for this component, refer to Restraint Systems, Air Bag Systems, Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Air bag Electronic Crash Sensor (ECS) module bolts .................................................................................................................................. 12 Nm (9 Lb-Ft) Driver air bag module bolts .................................................................................................................. ........................................................ 12 Nm (9 Lb-Ft) Passenger air bag module bolts ....................... .............................................................................................................................................. 9 Nm (80 Lb-In) Air bag sensor bolts .................................................................................................................. .................................................................... 12 Nm (9 Lb-Ft) Aft steering column nuts ....................... ...................................................................................................................................................... 15 Nm (11 Lb-Ft) Forwarded Steering column nuts ................................................................................. .............................................................................. 15 Nm (11 Lb-Ft) Crash sensor grounding screw weld nut repair screw (8 mm) ....................................................................................................................... 12 Nm (9 Lb-Ft) Grounding screw (6 mm) ..................................................................................................................... ......................................................... 12 Nm (9 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7565 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7566 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7567 Air Bag Control Module: Service Precautions WARNING: - The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have deployed. In addition, make sure the area of the (ECS) mounting is restored to its original condition. - If installing a new air bag module, always install a new air bag electronic crash sensor (ECS) module. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7568 Air Bag Control Module: Description and Operation The air bag Electronic Crash Sensor (ECS) module performs the following functions: - signals the inflators to deploy the air bags in the event of a deployable crash. - monitors the air bag Supplemental Restraint System (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). - signals the Lighting Control Module (LCM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the ECS and is not serviced separately. The ECS monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the ECS will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will flash the two-digit LFC. The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The ECS will also communicate the current and historical DTCs the DLC, using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system detects a fault condition, the ECS will signal the LCM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After the fault has been corrected, the next highest priority fault will be displayed. The ECS includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors close. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7569 Air Bag Control Module: Service and Repair REMOVAL WARNING: - The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have deployed. In addition, make sure the area of the (ECS) mounting is restored to its original condition. - If installing a new air bag module, always install a new air bag electronic crash sensor (ECS) module. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the RH sill plate. 3. Position the carpet out of the way. 4. Remove the ECS. 1 Disconnect the ECS electrical connector locking clip. 2 Disconnect the ECS electrical connector. 3 Remove the three retaining screws. 4 Remove the ECS module and bracket. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7570 1. Follow the removal procedure in reverse order. WARNING: The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have deployed. In addition, make sure the area of the (ECS) mounting is restored to its original condition. - If installing a new air bag module, always install a new air bag electronic crash sensor (ECS) module. - The tightening torque of the air bag electronic crash sensor (ECS) module bracket retaining screws is critical for correct system operation. NOTE: Make sure to tighten the retaining bolts to specification. - A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedures 1. Disconnect the battery ground cable and wait at least one minute. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedures 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Install the passenger air bag module. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 7577 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the vehicle battery connected? Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation If a child safety belt anchor tether is required for the child safety seat, a child safety belt anchor tether kit can be obtained free from any Ford or Lincoln-Mercury dealer. Attachment holes at each rear seating position have been provided in all vehicles. WARNING: It is important that the bolt/anchor be securely tightened to specification. Otherwise, the child safety seat may not be correctly secured and the child could be injured in case of a sudden stop or accident. Instructions for installing the child safety belt anchor tether kit are included in the kit with the tether attachment. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement Technical Service Bulletin # 00S15 Date: 000901 Recall - Seat Belt Retractor Inspection/Replacement SAFETY RECALL 00S15 Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which Had the Left Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor inspection and, if Necessary, Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7590 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7591 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of Lip to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7592 DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, give the owner a copy of the owner letter and arrange for a service date. NOTE: Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the instructions of Attachment IV. RENTAL CARS If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel, which will be at the owner's expense. Rentals should be provided only while the vehicle is at the dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. NOTE: Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7593 PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as noted below: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7594 Table 1 * # 150 * Crown Victoria/Grand Marquis NOTE: Please use the chart only until the next publication of the Service Parts Catalog (September, 2000). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7595 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7596 Table 2 **150* Town Car DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7597 EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information LEFT FRONT SAFETY BELT RETRACTOR OVERVIEW This procedure will require the technician to locate and inspect the build label for the front left-hand seat belt retractor. The build label is located at one of two possible places on the seat belt webbing. Some minor disassembly may be required to access the build label. An affected seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected by the build date will be replaced. Follow the appropriate procedure in the workshop manual. LOCATING BUILD LABEL NOTE: The build label is located either on the seat belt webbing above the anchor boot or under the anchor boot. 1. Locate the build label on the webbing of the front left-hand seat belt retractor as follows: ^ Look for the build label on the webbing directly above the anchor boot. If the build label is located here proceed to Label Inspection. If the label is not located here proceed to the next bullet point. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7598 ^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection. LABEL INSPECTION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7599 1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date Code Translator chart to determine the build date. 2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R) and must be replaced. a. If you have determined the seat belt must be replaced based on the build date, replace the seat belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate workshop manual. NOTE: Some of the safety belt retractors received from Ford Customer Service Division for the affected vehicles have been reworked to include a stowage clip. Retractors with stowage clips are acceptable regardless of date code. b. If you have determined the seat belt does not need replacement, reassemble the retractor (if disassembly is required) as follows: ^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the anchor boot. ^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft). ^ Install the anchor bolt cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7600 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7601 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7602 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7603 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7604 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement Technical Service Bulletin # 00S16 Date: 000901 Recall - Seat Belt Inspection/Replacement 00S16 SAFETY RECALL Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which Had the Right Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor Inspection and, If Necessary, Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7609 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7610 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7611 DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, give the owner a copy of the owner letter and arrange for a service date. NOTE: Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the instructions on Attachment IV. RENTAL CARS If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel, which will be at the owner's expense. Rentals should be provided only while the vehicle is at the dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. NOTE: Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7612 PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as noted below: NOTE: Please use the chart only until the next publication of the Service Parts Catalog (September, 2000). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7613 Table 1 * # 150 * Crown Victoria/Grand Marquis Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7614 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7615 Table 2 * # 150 * Town Car DEALER PRICE For latest prices refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information RIGHT FRONT SAFETY BELT RETRACTOR OVERVIEW This procedure will require the technician to locate and inspect the build label for the front right-hand seat belt retractor. The build label is located at one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7616 of two possible places on the seat belt webbing. Some minor disassembly may be required to access the build label. An affected seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected by the build date will be replaced. Follow the appropriate procedure in the workshop manual. LOCATING BUILD LABEL NOTE: The build label is located either on the seat belt webbing above the anchor boot or under the anchor boot. 1. Locate the build label on the webbing of the front right-hand seat belt retractor as follows: ^ Look for the build label on the webbing directly above the anchor boot. If the build label is located here proceed to Label Inspection. If the label is not located here proceed to the next bullet point. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7617 ^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection. LABEL INSPECTION 1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date Code Translator chart to determine the build date. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7618 2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R) and must be replaced. a. If you have determined the seat belt must be replaced based on the build date, replace the seat belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate workshop manual. NOTE: Some of the safety belt retractors received from Ford Customer Service Division for the affected vehicles have been reworked to include a stowage clip. Retractors with stowage clips are acceptable regardless of date code. b. If you have determined the seat belt does not need replacement, reassemble the retractor (if disassembly is required) as follows: ^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the anchor boot. ^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft). ^ Install the anchor bolt cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7619 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7620 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7621 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7622 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7623 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > NHTSA00V157001 > Jun > 00 > Recall 00V157001: Service Stock Seat Belt Assemblies Seat Belt: Recalls Recall 00V157001: Service Stock Seat Belt Assemblies Vehicle Description: Passenger vehicles using aftermarket driver's seat belt assemblies that were sold by Ford Parts Departments from January 1, through June 13, 2000. These seat belt assemblies fail to comply with the requirements of FMVSS No. 209, "Seat Belt Assemblies." The equipment involved is Service Stock Seat Belt Assemblies, Model Nos. H 9977, H 9979, T 9063, and T 9217, built by TRW Vehicle Safety Systems, Inc. (TRW) manufactured from June 1, 1998 through May 21, 2000. Some of these seat belt assemblies may have been installed as service replacement equipment on the vehicles involved in there call. In the event of a collision, these seat belts may not restrain an occupant increasing the risk of injury. Dealers will inspect these vehicles and replace the Service Seat Belt Assemblies that were installed in these vehicles from January 1 through June 13, 2000. Owner notification is expected to begin during late July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1996 FORD CROWN VICTORIA 1996 LINCOLN TOWN CAR 1996 MERCURY GRAND MARQUIS 1997 FORD CROWN VICTORIA 1997 LINCOLN TOWN CAR 1997 MERCURY GRAND MARQUIS 1998 FORD CROWN VICTORIA 1998 LINCOLN TOWN CAR 1998 MERCURY GRAND MARQUIS 1999 FORD CROWN VICTORIA 1999 LINCOLN TOWN CAR 1999 MERCURY GRAND MARQUIS 2000 FORD CROWN VICTORIA 2000 LINCOLN TOWN CAR 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > NHTSA00V157002 > Jun > 00 > Recall 00V157002: Service Stock Seat Belt Assemblies Seat Belt: Recalls Recall 00V157002: Service Stock Seat Belt Assemblies Vehicle Description: Passenger vehicles using aftermarket front passenger side seat belt assemblies that were sold by Ford Parts Departments from January 1, through June 13, 2000. These seat belt assemblies fail to comply with the requirements of FMVSS No. 209, "Seat Belt Assemblies." The equipment involved is Service Stock Seat Belt Assemblies, Model Nos. H 9977, H 9979, T 9063, and T 9217, built by TRW Vehicle Safety Systems, Inc. (TRW) manufactured from June 1, 1998 through May 21, 2000. Some of these seat belt assemblies may have been installed as service replacement equipment on the vehicles involved in the recall. In the event of a collision, these seat belts may not restrain an occupant increasing the risk of injury. Dealers will inspect these vehicles and replace the Service Seat Belt Assemblies that were installed in these vehicles from January 1 through June 13, 2000. Owner notification is expected to begin during late July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1996 FORD CROWN VICTORIA 1996 LINCOLN TOWN CAR 1996 MERCURY GRAND MARQUIS 1997 FORD CROWN VICTORIA 1997 LINCOLN TOWN CAR 1997 MERCURY GRAND MARQUIS 1998 FORD CROWN VICTORIA 1998 LINCOLN TOWN CAR 1998 MERCURY GRAND MARQUIS 1999 FORD CROWN VICTORIA 1999 LINCOLN TOWN CAR 1999 MERCURY GRAND MARQUIS 2000 FORD CROWN VICTORIA 2000 LINCOLN TOWN CAR 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement Technical Service Bulletin # 00S15 Date: 000901 Recall - Seat Belt Retractor Inspection/Replacement SAFETY RECALL 00S15 Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which Had the Left Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor inspection and, if Necessary, Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7637 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7638 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of Lip to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7639 DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, give the owner a copy of the owner letter and arrange for a service date. NOTE: Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the instructions of Attachment IV. RENTAL CARS If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel, which will be at the owner's expense. Rentals should be provided only while the vehicle is at the dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. NOTE: Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7640 PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as noted below: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7641 Table 1 * # 150 * Crown Victoria/Grand Marquis NOTE: Please use the chart only until the next publication of the Service Parts Catalog (September, 2000). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7642 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7643 Table 2 **150* Town Car DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7644 EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information LEFT FRONT SAFETY BELT RETRACTOR OVERVIEW This procedure will require the technician to locate and inspect the build label for the front left-hand seat belt retractor. The build label is located at one of two possible places on the seat belt webbing. Some minor disassembly may be required to access the build label. An affected seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected by the build date will be replaced. Follow the appropriate procedure in the workshop manual. LOCATING BUILD LABEL NOTE: The build label is located either on the seat belt webbing above the anchor boot or under the anchor boot. 1. Locate the build label on the webbing of the front left-hand seat belt retractor as follows: ^ Look for the build label on the webbing directly above the anchor boot. If the build label is located here proceed to Label Inspection. If the label is not located here proceed to the next bullet point. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7645 ^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection. LABEL INSPECTION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7646 1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date Code Translator chart to determine the build date. 2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R) and must be replaced. a. If you have determined the seat belt must be replaced based on the build date, replace the seat belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate workshop manual. NOTE: Some of the safety belt retractors received from Ford Customer Service Division for the affected vehicles have been reworked to include a stowage clip. Retractors with stowage clips are acceptable regardless of date code. b. If you have determined the seat belt does not need replacement, reassemble the retractor (if disassembly is required) as follows: ^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the anchor boot. ^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft). ^ Install the anchor bolt cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7647 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7648 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7649 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7650 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7651 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement Technical Service Bulletin # 00S16 Date: 000901 Recall - Seat Belt Inspection/Replacement 00S16 SAFETY RECALL Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which Had the Right Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor Inspection and, If Necessary, Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7656 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7657 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7658 DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, give the owner a copy of the owner letter and arrange for a service date. NOTE: Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the instructions on Attachment IV. RENTAL CARS If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel, which will be at the owner's expense. Rentals should be provided only while the vehicle is at the dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. NOTE: Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7659 PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as noted below: NOTE: Please use the chart only until the next publication of the Service Parts Catalog (September, 2000). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7660 Table 1 * # 150 * Crown Victoria/Grand Marquis Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7661 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7662 Table 2 * # 150 * Town Car DEALER PRICE For latest prices refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information RIGHT FRONT SAFETY BELT RETRACTOR OVERVIEW This procedure will require the technician to locate and inspect the build label for the front right-hand seat belt retractor. The build label is located at one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7663 of two possible places on the seat belt webbing. Some minor disassembly may be required to access the build label. An affected seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected by the build date will be replaced. Follow the appropriate procedure in the workshop manual. LOCATING BUILD LABEL NOTE: The build label is located either on the seat belt webbing above the anchor boot or under the anchor boot. 1. Locate the build label on the webbing of the front right-hand seat belt retractor as follows: ^ Look for the build label on the webbing directly above the anchor boot. If the build label is located here proceed to Label Inspection. If the label is not located here proceed to the next bullet point. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7664 ^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection. LABEL INSPECTION 1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date Code Translator chart to determine the build date. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7665 2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R) and must be replaced. a. If you have determined the seat belt must be replaced based on the build date, replace the seat belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate workshop manual. NOTE: Some of the safety belt retractors received from Ford Customer Service Division for the affected vehicles have been reworked to include a stowage clip. Retractors with stowage clips are acceptable regardless of date code. b. If you have determined the seat belt does not need replacement, reassemble the retractor (if disassembly is required) as follows: ^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the anchor boot. ^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft). ^ Install the anchor bolt cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7666 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7667 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7668 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7669 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7670 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA00V157001 > Jun > 00 > Recall 00V157001: Service Stock Seat Belt Assemblies Seat Belt: All Technical Service Bulletins Recall 00V157001: Service Stock Seat Belt Assemblies Vehicle Description: Passenger vehicles using aftermarket driver's seat belt assemblies that were sold by Ford Parts Departments from January 1, through June 13, 2000. These seat belt assemblies fail to comply with the requirements of FMVSS No. 209, "Seat Belt Assemblies." The equipment involved is Service Stock Seat Belt Assemblies, Model Nos. H 9977, H 9979, T 9063, and T 9217, built by TRW Vehicle Safety Systems, Inc. (TRW) manufactured from June 1, 1998 through May 21, 2000. Some of these seat belt assemblies may have been installed as service replacement equipment on the vehicles involved in there call. In the event of a collision, these seat belts may not restrain an occupant increasing the risk of injury. Dealers will inspect these vehicles and replace the Service Seat Belt Assemblies that were installed in these vehicles from January 1 through June 13, 2000. Owner notification is expected to begin during late July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1996 FORD CROWN VICTORIA 1996 LINCOLN TOWN CAR 1996 MERCURY GRAND MARQUIS 1997 FORD CROWN VICTORIA 1997 LINCOLN TOWN CAR 1997 MERCURY GRAND MARQUIS 1998 FORD CROWN VICTORIA 1998 LINCOLN TOWN CAR 1998 MERCURY GRAND MARQUIS 1999 FORD CROWN VICTORIA 1999 LINCOLN TOWN CAR 1999 MERCURY GRAND MARQUIS 2000 FORD CROWN VICTORIA 2000 LINCOLN TOWN CAR 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA00V157002 > Jun > 00 > Recall 00V157002: Service Stock Seat Belt Assemblies Seat Belt: All Technical Service Bulletins Recall 00V157002: Service Stock Seat Belt Assemblies Vehicle Description: Passenger vehicles using aftermarket front passenger side seat belt assemblies that were sold by Ford Parts Departments from January 1, through June 13, 2000. These seat belt assemblies fail to comply with the requirements of FMVSS No. 209, "Seat Belt Assemblies." The equipment involved is Service Stock Seat Belt Assemblies, Model Nos. H 9977, H 9979, T 9063, and T 9217, built by TRW Vehicle Safety Systems, Inc. (TRW) manufactured from June 1, 1998 through May 21, 2000. Some of these seat belt assemblies may have been installed as service replacement equipment on the vehicles involved in the recall. In the event of a collision, these seat belts may not restrain an occupant increasing the risk of injury. Dealers will inspect these vehicles and replace the Service Seat Belt Assemblies that were installed in these vehicles from January 1 through June 13, 2000. Owner notification is expected to begin during late July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1996 FORD CROWN VICTORIA 1996 LINCOLN TOWN CAR 1996 MERCURY GRAND MARQUIS 1997 FORD CROWN VICTORIA 1997 LINCOLN TOWN CAR 1997 MERCURY GRAND MARQUIS 1998 FORD CROWN VICTORIA 1998 LINCOLN TOWN CAR 1998 MERCURY GRAND MARQUIS 1999 FORD CROWN VICTORIA 1999 LINCOLN TOWN CAR 1999 MERCURY GRAND MARQUIS 2000 FORD CROWN VICTORIA 2000 LINCOLN TOWN CAR 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 7679 Seat Belt: Specifications Front retractor bolt ............................................................................................................................... ....................................................... 40 Nm (30 Lb-Ft) Rear retractor bolt ........................................... ............................................................................................................................................ 40 Nm (30 Lb-Ft) Front safety belt to floor pan ..................................................................................................... .................................................................. 40 Nm (30 Lb-Ft) Rear safety belt to floor pan bolt .......... ...................................................................................................................................................... 48 Nm (35 Lb-Ft) Rear safety belt buckle/buckle combination to floor pan bolt ..................................................................................................................... 48 Nm (35 Lb-Ft) Rear safety belt buckle/belt combination to floor pan bolt ......................................................................................................................... 48 Nm (35 Lb-Ft) Height adjuster bolt .............................................................................................................................. ...................................................... 40 Nm (30 Lb-Ft) Front safety belt buckle to seat nut ............................................................................................................................................................. 40 Nm (30 Lb-Ft) Front center safety belt to driver seat track nut .......................................................................................................................................... 80 Nm (59 Lb-Ft) D-ring nut .................................................................................................................................. ................................................................. 40 Nm (30 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 7680 Seat Belt: Description and Operation While the vehicle is in motion, the combination lap and shoulder belt adjusts to the occupant's movement. However, if the vehicle is braked hard, cornered hard or if the vehicle receives an impact of 8 km/h (5 mph) or more, the lap and shoulder belt locks and helps reduce the occupant's forward movement. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection Seat Belt: Service and Repair Cleaning and Inspection 1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. WARNING: Do not bleach or re-dye the webbing, as the webbing may weaken. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7683 Seat Belt: Service and Repair Removal and Installation Front Buckle End Driver and Front Passenger Seat 1. Remove the front seat. Driver Side Only 2. Disconnect the connector. 3. Remove the nut. 4. Remove the safety belt buckle through the seat cushion opening. INSTALLATION 1. To install, reverse the removal procedure. 2. Make sure the center passenger restraint is correctly routed through the seat cushion opening and is not twisted. Check the restraint system for correct operation. Height Adjuster-Front REMOVAL 1. Remove the upper B-pillar. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7684 2. Remove the height adjuster. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Rear Seat Buckle End REMOVAL 1. Remove the rear seat cushion. 2. Remove the buckle. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7685 1. To install, reverse the removal procedure. 2. Make sure the safety belt buckles are routed correctly and are placed on the seat cushion. 3. Check the restraint system for correct operation. Retractor and Tongue - Front Seats REMOVAL 1. Remove the front door scuff plate. 2. Remove the rear door scuff plate. 3. Pull back the weatherstrips. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7686 4. Remove the cover. 5. Remove the bolt. 6. Remove the center body pillar lower finish panel. 7. Remove the cover. 8. Remove the nut. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7687 9. Remove the screw. 10. Remove the retractor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7688 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Retractor and Tongue - Rear Seats REMOVAL 1. Remove the package tray trim panel. 2. Remove the retractor. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Safety Belt-Front Center REMOVAL 1. Remove the driver seat safety belt buckle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7689 2. Remove the front seat center safety belt. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7690 Seat Belt: Service and Repair Safety Belt Maintenance and Inspection WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar, if equipped), shoulder belt height adjuster (if equipped), child safety seat tether bracket assemblies (if equipped) and attaching hardware should be inspected after any collision. New safety belt assemblies should be installed unless a qualified technician finds that the belts show no damage and operate correctly. Safety belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. 1. The safety belt assemblies should be periodically inspected to make sure that they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress. 2. Before installing the new safety belt assembly; the safety belt retaining areas must be inspected for damage and distortion. If the retaining points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. 3. Install the new safety belt(s). 4. Carry out the Functional Test. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7691 Seat Belt: Service and Repair Service Procedures Parts Replacement Chart Code Letter .......................................................................................................................................... .................................................................Part Name 1K .................................................................................................................................................. Bolt-7/16-2 x 1.38 Pan Shoulder Tapping-0.50 Shoulder 1M .............................................................. .............................................................................................................. Bolt-7/16-20 x 1.15 Pan Head Tapping 1B ................................................................................................................................................ Bolt-7/16-20 x 1.15 Pan Shoulder Tapping-0.50 Shoulder 2Y ............................................................ ...................................................................................................... Bolt-1/2-13 x 1.5 Pan Head Shoulder Locking Post Collision Inspection WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar, if so equipped), shoulder belt height adjuster (if equipped), child safety seat tether bracket assemblies (if equipped) and attaching hardware should be inspected after any collision. New safety belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Safety belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. 1. Before installing a 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 worked back to its original shape and structural integrity. 2. Install the new safety belt(s). 3. Carry out the Functional Test. Safety Belt Tongue Rotated on Belt 1. Grasp the belt tongue and pull the belt webbing down to form a loop through the upper (longer and narrower) slot in the tongue. 2. Rotate and fold the belt webbing over itself within the slot to remove the twist. 3. Pull the excess belt webbing back through the upper slot in the belt tongue. 4. Grasp the belt tongue and pull the belt webbing up to form a loop through the low slot in the tongue. 5. Rotate and fold the belt webbing over itself within the slot to remove the twist. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7692 6. Pull the excess belt webbing through the slot. 7. The safety belt tongue should face inward when completed. Seat Belt With Anchor Plate Thread Damage 1. Remove the broken or stripped bolt. NOTE: The lap/shoulder safety belts are factory-installed in their correct locations. If the safety belts are removed for any reason, they must be installed. The 7/16 x 20 Torx (R) head anchor bolts must be hand-started and then tightened to 40 Nm (30 lb-ft). 2. Drill out the internal threads in the safety belt anchor plate with a 27/64-inch drill. 3. Rethread the anchor plate with a 1/2-13 tap. 4. Blow out the chips. 5. Install the attachment parts in the correct sequence. For additional information, refer to Safety Belt Buckle-Front or Safety Belt Buckle-Rear. Install a new bolt, hand-tighten and then tighten the bolt to 40 Nm (30 lb-ft). NOTE: Refer to the Parts Replacement Chart when installing new parts. Seat Belt Without Anchor Plate Thread Damage The seat and shoulder safety belts are factory-installed in their proper locations. If the belts are removed for any reason, they MUST be installed. The 7/16-inch x 20 TORX (R) head anchor bolts must be hand-started and then tightened to 40 Nm (30 lb-ft). 1. Remove damaged bolt from anchor reinforcement and discard. 2. Install a new bolt by hand. Tighten to 40 Nm (30 lb-ft). Shoulder Strap Adjuster With Stripped Weld Nuts, Front Seat D - Ring Installation Kit Special Tool(s) 1. Remove the shoulder safety belt height adjuster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7693 2. Use the one-half inch drill provided in the special tool kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap provided in the special tool kit and tap new threads. NOTE: After each rotation, back off the tap slightly to remove the new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert provided in the special tool kit and screw it into the retapped hole until it is slightly below the surface. 5. Use a hammer to tap the installation tool provided in the special tool kit several times to seat the insert keys. NOTE: Refer to Height Adjuster-Front if the two bolts on the height adjuster are not stripped. If the bolts are stripped, install a new height adjuster. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7694 6. Insert the shoulder safety belt height adjuster in the opening of the upper B-pillar structure, making sure the shoulder belt height adjuster knob on the shoulder safety belt height adjuster is positioned above the D-ring attachment nut. (The tab is located at the top and is to be inserted in the hole provided in the B-pillar structure). NOTE: If the two Torx (R) head retaining bolts on the shoulder safety belt height adjuster are not stripped, install the shoulder safety belt height adjuster to the body structure as stated in this step. If the front seat shoulder strap adjuster retaining bolts are stripped, install a new shoulder safety belt height adjuster. 7. Hand tighten the bolts until they are snug. 8. Tighten the bolts. 9. Install the B-pillar trim. 10. Operate the front seat shoulder strap adjuster. Make sure it travels from top to bottom and locks correctly in each position. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7695 11. Install the safety belt D-ring and tighten the nut. 12. Install the D-ring cover. Make sure the safety belt D-ring rotates freely. 13. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation Seat Belt Buckle: Description and Operation The inboard front safety belt buckle end-LH, front safety belt buckle end RH is secured to the front seat track. The center safety belt is attached to the floor pan through a slot in the seat track. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Buckle End - Rear Seats Seat Belt Buckle: Service and Repair Buckle End - Rear Seats REMOVAL 1. Remove the rear seat cushion. 2. Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. 2. Make sure the safety belt buckles are routed correctly and are placed on the seat cushion. 3. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Buckle End - Rear Seats > Page 7701 Seat Belt Buckle: Service and Repair Buckle End - Front Seats Driver and Front Passenger Seat 1. Remove the front seat. Driver Side Only 2. Disconnect the connector. 3. Remove the nut. 4. Remove the safety belt buckle through the seat cushion opening. INSTALLATION 1. To install, reverse the removal procedure. 2. Make sure the center passenger restraint is correctly routed through the seat cushion opening and is not twisted. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation A safety belt that is too short even when fully extended can be lengthened. The safety belt extension is available. This assembly will add approximately 20 cm (8 inches) to the length of the safety belt. Use the safety belt extension only if the safety belt is too short when fully extended. Do not use the safety belt extension to alter the fit of the shoulder belt across the torso. Safety belt extensions are available at no cost from any authorized Ford or Lincoln-Mercury dealer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Description ........................................................................................................................................... ............................................................ N.m (Lb-Ft) Front Seat Shoulder Strap Adjuster Bolt .................................................................................................................................................... 40 Nm (30 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications > Page 7708 Seat Belt Height Adjuster: Service and Repair REMOVAL 1. Remove the upper B-pillar. 2. Remove the height adjuster. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Fasten Belts Indicator <--> [Seat Belt Reminder Lamp] > Component Information > Description and Operation Fasten Belts Indicator: Description and Operation The safety belt indicator is directly hardwired to the Lighting Control Module (LCM). The LCM controls the safety belt indicator depending on the signal it receives from the safety belt buckle switch. The safety belt indicator illuminates when the safety belt is not buckled, closing the safety belt buckle switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement Technical Service Bulletin # 00S15 Date: 000901 Recall - Seat Belt Retractor Inspection/Replacement SAFETY RECALL 00S15 Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which Had the Left Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor inspection and, if Necessary, Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7720 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7721 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of Lip to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7722 DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, give the owner a copy of the owner letter and arrange for a service date. NOTE: Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the instructions of Attachment IV. RENTAL CARS If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel, which will be at the owner's expense. Rentals should be provided only while the vehicle is at the dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. NOTE: Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7723 PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as noted below: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7724 Table 1 * # 150 * Crown Victoria/Grand Marquis NOTE: Please use the chart only until the next publication of the Service Parts Catalog (September, 2000). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7725 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7726 Table 2 **150* Town Car DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7727 EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information LEFT FRONT SAFETY BELT RETRACTOR OVERVIEW This procedure will require the technician to locate and inspect the build label for the front left-hand seat belt retractor. The build label is located at one of two possible places on the seat belt webbing. Some minor disassembly may be required to access the build label. An affected seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected by the build date will be replaced. Follow the appropriate procedure in the workshop manual. LOCATING BUILD LABEL NOTE: The build label is located either on the seat belt webbing above the anchor boot or under the anchor boot. 1. Locate the build label on the webbing of the front left-hand seat belt retractor as follows: ^ Look for the build label on the webbing directly above the anchor boot. If the build label is located here proceed to Label Inspection. If the label is not located here proceed to the next bullet point. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7728 ^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection. LABEL INSPECTION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7729 1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date Code Translator chart to determine the build date. 2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R) and must be replaced. a. If you have determined the seat belt must be replaced based on the build date, replace the seat belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate workshop manual. NOTE: Some of the safety belt retractors received from Ford Customer Service Division for the affected vehicles have been reworked to include a stowage clip. Retractors with stowage clips are acceptable regardless of date code. b. If you have determined the seat belt does not need replacement, reassemble the retractor (if disassembly is required) as follows: ^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the anchor boot. ^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft). ^ Install the anchor bolt cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7730 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7731 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7732 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7733 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7734 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement Technical Service Bulletin # 00S16 Date: 000901 Recall - Seat Belt Inspection/Replacement 00S16 SAFETY RECALL Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which Had the Right Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor Inspection and, If Necessary, Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7739 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7740 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7741 DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, give the owner a copy of the owner letter and arrange for a service date. NOTE: Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the instructions on Attachment IV. RENTAL CARS If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel, which will be at the owner's expense. Rentals should be provided only while the vehicle is at the dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. NOTE: Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7742 PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as noted below: NOTE: Please use the chart only until the next publication of the Service Parts Catalog (September, 2000). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7743 Table 1 * # 150 * Crown Victoria/Grand Marquis Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7744 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7745 Table 2 * # 150 * Town Car DEALER PRICE For latest prices refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information RIGHT FRONT SAFETY BELT RETRACTOR OVERVIEW This procedure will require the technician to locate and inspect the build label for the front right-hand seat belt retractor. The build label is located at one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7746 of two possible places on the seat belt webbing. Some minor disassembly may be required to access the build label. An affected seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected by the build date will be replaced. Follow the appropriate procedure in the workshop manual. LOCATING BUILD LABEL NOTE: The build label is located either on the seat belt webbing above the anchor boot or under the anchor boot. 1. Locate the build label on the webbing of the front right-hand seat belt retractor as follows: ^ Look for the build label on the webbing directly above the anchor boot. If the build label is located here proceed to Label Inspection. If the label is not located here proceed to the next bullet point. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7747 ^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection. LABEL INSPECTION 1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date Code Translator chart to determine the build date. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7748 2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R) and must be replaced. a. If you have determined the seat belt must be replaced based on the build date, replace the seat belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate workshop manual. NOTE: Some of the safety belt retractors received from Ford Customer Service Division for the affected vehicles have been reworked to include a stowage clip. Retractors with stowage clips are acceptable regardless of date code. b. If you have determined the seat belt does not need replacement, reassemble the retractor (if disassembly is required) as follows: ^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the anchor boot. ^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft). ^ Install the anchor bolt cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7749 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7750 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7751 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7752 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7753 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement Technical Service Bulletin # 00S15 Date: 000901 Recall - Seat Belt Retractor Inspection/Replacement SAFETY RECALL 00S15 Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which Had the Left Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor inspection and, if Necessary, Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7759 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7760 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of Lip to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7761 DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, give the owner a copy of the owner letter and arrange for a service date. NOTE: Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the instructions of Attachment IV. RENTAL CARS If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel, which will be at the owner's expense. Rentals should be provided only while the vehicle is at the dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. NOTE: Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7762 PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as noted below: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7763 Table 1 * # 150 * Crown Victoria/Grand Marquis NOTE: Please use the chart only until the next publication of the Service Parts Catalog (September, 2000). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7764 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7765 Table 2 **150* Town Car DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7766 EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information LEFT FRONT SAFETY BELT RETRACTOR OVERVIEW This procedure will require the technician to locate and inspect the build label for the front left-hand seat belt retractor. The build label is located at one of two possible places on the seat belt webbing. Some minor disassembly may be required to access the build label. An affected seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected by the build date will be replaced. Follow the appropriate procedure in the workshop manual. LOCATING BUILD LABEL NOTE: The build label is located either on the seat belt webbing above the anchor boot or under the anchor boot. 1. Locate the build label on the webbing of the front left-hand seat belt retractor as follows: ^ Look for the build label on the webbing directly above the anchor boot. If the build label is located here proceed to Label Inspection. If the label is not located here proceed to the next bullet point. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7767 ^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection. LABEL INSPECTION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7768 1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date Code Translator chart to determine the build date. 2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R) and must be replaced. a. If you have determined the seat belt must be replaced based on the build date, replace the seat belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate workshop manual. NOTE: Some of the safety belt retractors received from Ford Customer Service Division for the affected vehicles have been reworked to include a stowage clip. Retractors with stowage clips are acceptable regardless of date code. b. If you have determined the seat belt does not need replacement, reassemble the retractor (if disassembly is required) as follows: ^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the anchor boot. ^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft). ^ Install the anchor bolt cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7769 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7770 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7771 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7772 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7773 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement Technical Service Bulletin # 00S16 Date: 000901 Recall - Seat Belt Inspection/Replacement 00S16 SAFETY RECALL Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which Had the Right Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor Inspection and, If Necessary, Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7778 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7779 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7780 DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, give the owner a copy of the owner letter and arrange for a service date. NOTE: Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the instructions on Attachment IV. RENTAL CARS If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel, which will be at the owner's expense. Rentals should be provided only while the vehicle is at the dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. NOTE: Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7781 PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as noted below: NOTE: Please use the chart only until the next publication of the Service Parts Catalog (September, 2000). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7782 Table 1 * # 150 * Crown Victoria/Grand Marquis Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7783 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7784 Table 2 * # 150 * Town Car DEALER PRICE For latest prices refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information RIGHT FRONT SAFETY BELT RETRACTOR OVERVIEW This procedure will require the technician to locate and inspect the build label for the front right-hand seat belt retractor. The build label is located at one Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7785 of two possible places on the seat belt webbing. Some minor disassembly may be required to access the build label. An affected seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected by the build date will be replaced. Follow the appropriate procedure in the workshop manual. LOCATING BUILD LABEL NOTE: The build label is located either on the seat belt webbing above the anchor boot or under the anchor boot. 1. Locate the build label on the webbing of the front right-hand seat belt retractor as follows: ^ Look for the build label on the webbing directly above the anchor boot. If the build label is located here proceed to Label Inspection. If the label is not located here proceed to the next bullet point. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7786 ^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection. LABEL INSPECTION 1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date Code Translator chart to determine the build date. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7787 2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R) and must be replaced. a. If you have determined the seat belt must be replaced based on the build date, replace the seat belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate workshop manual. NOTE: Some of the safety belt retractors received from Ford Customer Service Division for the affected vehicles have been reworked to include a stowage clip. Retractors with stowage clips are acceptable regardless of date code. b. If you have determined the seat belt does not need replacement, reassemble the retractor (if disassembly is required) as follows: ^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the anchor boot. ^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft). ^ Install the anchor bolt cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7788 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7789 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7790 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7791 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7792 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 7793 Seat Belt Retractor: Specifications Description ........................................................................................................................................... ............................................................ N.m (Lb-Ft) Front retractor bolt ............................................................................................................................... ....................................................... 40 Nm (30 Lb-Ft) Rear retractor bolt ........................................... ............................................................................................................................................ 40 Nm (30 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 7794 Seat Belt Retractor: Description and Operation WARNING: Rear-facing infant seats should never be placed in the front seats. The dual locking mode retractor on the shoulder belt portion of the combination lap/shoulder safety belt for the front seat passenger, rear seat outboard passengers and rear center passenger operates in two ways: 1. In the vehicle-sensitive (emergency locking) mode, the shoulder belt retractor will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering or impacts of approximately 8 km/h (5 mph) or more. The front and rear outboard seat belt retractors can also be made to lock by pulling/jerking on the belt. 2. In the automatic locking mode, the shoulder belt retractor will be automatically locked and remain locked when the combination lap/shoulder safety belt is buckled and does not allow the occupant freedom of movement. This mode provides tight lap/shoulder belt fit on the occupant and on a child safety seat or infant carrier installation restraint. When the combination lap/shoulder belt is unbuckled and allowed to retract completely, the retractor will switch to the vehicle sensitive (emergency locking) mode. The automatic locking mode must be used when installing a child safety seat on the front passenger seat and rear outboard seats where dual locking retractors are provided. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue Seat Belt Retractor: Service and Repair Front Seat Belt, Retractor and Tongue REMOVAL 1. Remove the front door scuff plate. 2. Remove the rear door scuff plate. 3. Pull back the weatherstrips. 4. Remove the cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7797 5. Remove the bolt. 6. Remove the center body pillar lower finish panel. 7. Remove the cover. 8. Remove the nut. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7798 9. Remove the screw. 10. Remove the retractor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7799 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7800 Seat Belt Retractor: Service and Repair Rear Seats REMOVAL 1. Remove the package tray trim panel. 2. Remove the retractor. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Description and Operation Seat Belt Warning Timer: Description and Operation The safety belt warning indicator light illuminates and a chime sounds to remind the occupants to fasten their safety belts. The conditions of operation for the safety belt warning indicator and chime are as follows: - If the driver safety belt is not buckled before the ignition switch is turned to ON, then the safety belt warning indicator illuminates for one to two minutes and the warning chime sounds for four to eight seconds. - If the driver safety belt is buckled while the warning indicator is illuminated and the reminder chime is sounding, then the safety belt warning indicator and reminder chime turn off. - If the driver safety belt is buckled before the ignition switch in turned to ON, then the safety belt warning indicator and reminder chime remain off. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air bag Electronic Crash Sensor (ECS) module bolts .................................................................................................................................. 12 Nm (9 Lb-Ft) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 7808 Impact Sensor: Service Precautions WARNING: - Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 7809 Impact Sensor: Service and Repair REMOVAL WARNING: - Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator upper sight shield. 3. Remove the air bag sensor. 1 Disconnect the air bag sensor electrical connector. 2 Remove the three screws. 3 Remove the air bag sensor. INSTALLATION 1. Follow the removal procedure in reverse order. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle shop manual to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 7810 auxiliary batteries and power supplies (if equipped). NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair Antenna: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair TSB 04-24-5 12/13/04 REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria, Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005 Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape 2004-2005 F-150, Freestar 2005 Escape Hybrid LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego 1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 04-18-9 to update vehicle applications and service procedure. ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass. ACTION Follow the diagnostic and repair procedures included in this article to inspect and service rear defroster grid lines, integral antenna concerns or broken terminal tabs. SERVICE PROCEDURE Warrantable/Non Warrantable repairs Warrantable grid line repairs typically can be identified by one inoperative grid line with a small discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are scratched or have the silver material removed are not warrantable and should be addressed with the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated Back Lite Damageability Job Aid for additional information and examples of defects and damage. NOTE THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 7816 THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS EXPLAINED IN THIS ARTICLE. Examples Of Non-Warrantable Grid Line Damage ^ Ice scraper damage to grid lines ^ Animal scratches on grid lines ^ Window tint film/removal of the film which damages grid lines ^ Stickers placed over grids which upon removal, removes the grid line material ^ License plate (steel type placed against the inside of back glass) which rubs on the grid line causing damage ^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal removes grid line material ^ Cargo or lumber rubbing against the glass which removes grid line material ^ Cellular phone antenna installation/removal which damages grid line material NOTE AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL ACROSS THEM. GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR 12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID LINE INOPERATIVE - DIAGNOSTICS 1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power and ground to the back-glass. 2. Connect a test lamp or DVOM to a good body ground. 3. Turn the ignition key to the run position and depress and release the rear defroster button to turn the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME THE DEFROSTER BUTTON IS PRESSED. 4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM + lead to each grid line. (Use caution not to damage grid lines). The DVOM should read approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test light, the bulb should be approximately the same brightness on each line from top to bottom. If the DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid line with the + test lead or test lamp until the voltage changes suddenly. This is the area of concern, use chalk to mark the area of concern and mark the outside of the glass at that same area. 5. Repair per the Grid Line Repair Procedure. GRID LINE REPAIR PROCEDURE NOTE LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE, HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE (5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID LINE AREAS. NOTE IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW DEFROSTER REPAIR COMPOUND. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 7817 Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or equivalent meeting Ford specification ESB-M4J58-A as follows: Surface Preparation 1. Bring vehicle inside and warm it to 60° F (16° C) or above. 2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. NOTE THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME. Mixing The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake frequently during use. Application 1. Mark location of open grid on the outside of the back window glass (performed in diagnostics). Place protective covering over the package tray as necessary. 2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should be at the center of the mask and tape gap must be no wider than the existing grid line. Other types of tape may be used but end results of the repair may not appear as visually acceptable due to ease of application and tape edge finish. 3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five (5) minutes drying time between coats) across the open grid line area using the brush applicator in the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area. Apply a minimum of six (6) coats of the grid repair compound. 4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown lacquer touch-up paint across the open line area first. Take care to paint only the area missing the color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at least five (5) minutes between coats. Apply six (6) coats of grid repair compound. NOTE THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 7818 TIME TO MATCH THE REST OF THE GRID. 5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step outside and inspect the repaired area. If the repair compound is visible above or below the grid, the excess can be removed. This may be done by placing a single-edge razor blade on the back window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better but may not be cosmetically appealing. CAUTION BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID LINES FUNCTION PROPERLY WHEN FINISHED. Curing The service coating will air-dry in approximately one (1) minute and the system can be energized after five minutes. Maximum hardness and adhesion occur after approximately 24 hours. SOLDER METHOD OF LEAD TERMINAL NOTE THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE. PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY. The new terminal will cover the original terminal location, but must be placed so that the new terminal conductive areas will be placed on a good conductive base. This area should be cleaned with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to improve appearance. CAUTION DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER. BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL. The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a visual indication when the terminal has reached the proper temperature to melt the solder on the terminal. When the proper temperature is achieved the temperature paint will liquefy and change color. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 7819 Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus, use type B (Figure 3). NOTE DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL. SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE BUSS-BAR ON GOOD CONDUCTIVE MATERIAL. 1. Place the replacement terminal over the original tab location making sure the conductive areas of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original location which does not have conductive material (figure 4). 2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle may allow the terminal to slip when the solder liquefies). 3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab. Energize the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint color completely changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30) seconds. 4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for another two (2) minutes before the wiring lead is attached to the terminal. 5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify operation. Parts Block Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 7820 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042405A Repair Grid Lines (Includes 0.7 Hr. Time To Diagnose And Recheck) 042405B Replace Terminal (Includes 0.4 Hr. Time To Diagnose And Recheck) 042405C Repair Grid Lines And 0.8 Hr. Replace Terminal (Includes Time To Diagnose And Recheck) DEALER CODING CONDITION BASIC PART NO. CODE 7042006 28 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Page 7821 Antenna: Specifications Antenna Isolator Module Nuts 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Page 7822 Antenna: Description and Operation The antenna is concealed on the inside of the rear window glass. The AM antenna consists of the rear window defroster grid and the FM antenna is the conductive tracing above the rear window defroster grid. The radio antenna uses an antenna isolator module mounted under the rear package tray trim panel to separate the AM signals, FM signals, and rear defroster power. The radio antenna uses a two-piece coaxial cable to connect the radio chassis to the antenna isolator module. The front antenna lead-in cable is connected to the audio unit and has an in-line connector at the right end of the instrument panel. The rear antenna cable connects at the right end of the instrument panel and runs along the rocker panel within the body main wiring harness. It separates from the harness at the quarter panel and runs behind Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Page 7823 the rear seat and up to the package tray where it connects to the antenna isolator module. A third coaxial cable connects the FM antenna to the antenna isolator module along the right side of the rear window. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna Antenna: Service and Repair Antenna 1. The antenna is integral to the back window glass and can be repaired, but not replaced separately. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7826 Antenna: Service and Repair Antenna - Grid Wire Repair Special Tools Special Tool(s) NOTE: Any breaks longer than 25.4 mm (1 in) in one grid cannot be repaired. The back window glass must be replaced. Breaks equal to or shorter than 25.4 mm (1 in) in the heated back window grid wire can be successfully repaired by using the following procedure: 1. Obtain the following repair kit: ^ Repair Kit Order Number 50-25-0584-0029. 2. The vehicle should be brought inside and allowed to reach 16°C (60°F) or above. 3. Clean the repair area with denatured alcohol. 4. Place the grid line mask over the break aligning the cut out slots on either side of the repair area. 5. Apply the epoxy to the repair area. 6. Remove the mask without disturbing the epoxy. 7. Use Heat Gun to heat the repair area for one to two minutes at a distance of about 25-50 mm (1-2 in). This procedure should heat the repair area to approximately 149°C (300°F). 8. The heated back window may be energized immediately after the repair. Optimum hardness and adhesion will occur after 24 hours. Do not disturb the repaired area until that time. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7827 Antenna: Service and Repair Antenna - Isolator Module REMOVAL 1. Remove the rear package tray trim. 2. Remove the roof side rear trim panels. 3. Position the AM antenna/rear window defroster cable aside. 1 Disconnect the electrical connectors. 2 Unclip the wire retainers. 3 Position the AM antenna/rear window defroster cable aside. 4. Remove the antenna isolator module nuts. 5. Remove the antenna isolator module. 1 Disconnect the electrical connector. 2 Disconnect the antenna cables. 3 Remove the antenna isolator module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7828 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7829 Antenna: Service and Repair Cable - Antenna Lead In, Front REMOVAL 1. Remove the audio unit. 2. Disengage the antenna cable guide. 3. Position the RH lower instrument panel insulator aside. 1 Remove the pin-type retainers. 2 Release the locking tab. 3 Remove the instrument panel lower insulator. ^ Disconnect the courtesy lamp. 4. Disconnect the radio antenna lead in-cable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7830 5. Remove the antenna cable bracket screw. 6. Remove the center carpet insert. 1 Remove the two pin-type retainers. 2 Remove the center carpet insert. 7. Remove the antenna lead-in cable. 1 Remove the three clips. 2 Remove the antenna lead-in cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7831 Antenna: Service and Repair Antenna 1. The antenna is integral to the back window glass and can be repaired, but not replaced separately. Antenna - Grid Wire Repair Special Tools Special Tool(s) NOTE: Any breaks longer than 25.4 mm (1 in) in one grid cannot be repaired. The back window glass must be replaced. Breaks equal to or shorter than 25.4 mm (1 in) in the heated back window grid wire can be successfully repaired by using the following procedure: 1. Obtain the following repair kit: ^ Repair Kit Order Number 50-25-0584-0029. 2. The vehicle should be brought inside and allowed to reach 16°C (60°F) or above. 3. Clean the repair area with denatured alcohol. 4. Place the grid line mask over the break aligning the cut out slots on either side of the repair area. 5. Apply the epoxy to the repair area. 6. Remove the mask without disturbing the epoxy. 7. Use Heat Gun to heat the repair area for one to two minutes at a distance of about 25-50 mm (1-2 in). This procedure should heat the repair area to approximately 149°C (300°F). 8. The heated back window may be energized immediately after the repair. Optimum hardness and adhesion will occur after 24 hours. Do not disturb the repaired area until that time. Antenna - Isolator Module REMOVAL 1. Remove the rear package tray trim. 2. Remove the roof side rear trim panels. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7832 3. Position the AM antenna/rear window defroster cable aside. 1 Disconnect the electrical connectors. 2 Unclip the wire retainers. 3 Position the AM antenna/rear window defroster cable aside. 4. Remove the antenna isolator module nuts. 5. Remove the antenna isolator module. 1 Disconnect the electrical connector. 2 Disconnect the antenna cables. 3 Remove the antenna isolator module. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7833 Cable - Antenna Lead In, Front REMOVAL 1. Remove the audio unit. 2. Disengage the antenna cable guide. 3. Position the RH lower instrument panel insulator aside. 1 Remove the pin-type retainers. 2 Release the locking tab. 3 Remove the instrument panel lower insulator. ^ Disconnect the courtesy lamp. 4. Disconnect the radio antenna lead in-cable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7834 5. Remove the antenna cable bracket screw. 6. Remove the center carpet insert. 1 Remove the two pin-type retainers. 2 Remove the center carpet insert. 7. Remove the antenna lead-in cable. 1 Remove the three clips. 2 Remove the antenna lead-in cable. INSTALLATION 1. To install, reverse the removal procedure. Cable - Antenna Lead In, Rear REMOVAL CAUTION: The antenna lead-in cable is not removable from the wiring harness. If the cable needs to be replaced, leave it in the wiring harness. Install a new cable on top of the body main wiring harness and secure it with wire ties. Do not cut into the wiring harness to remove the existing antenna lead-in cable. 1. Disconnect the battery ground cable. 2. Remove the package tray trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7835 3. Remove the roof side rear trim panels. 4. Remove the RH front and rear scuff plates. NOTE: RH front shown, all others similar. 5. Remove the lower quarter trim panel. 6. Remove the B-pillar trim panel. 7. Remove the RH instrument panel lower insulator. 1 Remove the pin-type retainers. 2 Release the locking tab. 3 Remove the instrument panel lower insulator. ^ Disconnect the courtesy lamp. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7836 8. Remove the A-pillar lower trim panel. 9. Disconnect the radio antenna lead-in cable. 10. Disconnect the radio antenna lead-in cable. INSTALLATION CAUTION: The antenna lead-in cable is not removable from the wiring harness. If the cable needs to be replaced, leave it in the wiring harness. Install a new cable on top of the body main wiring harness and secure it with wire ties. Do not cut into the wiring harness to remove the existing antenna lead in cable. Tie back or insulate the old cable ends to keep them from causing noise. 1. Connect the antenna lead-in cable at the antenna isolator module. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7837 2. Install the new antenna lead-in cable on top of the old one and secure it with wire ties. 3. Install the new antenna lead-in cable in the wiring harness conduit along the rocker panel. 4. Connect the antenna lead-in cable. 5. Install the A-pillar lower trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7838 6. Install the instrument panel lower insulator. 1 Position the RH instrument panel lower insulator. 2 Engage the locking tab. 3 Install the pin-type retainers. ^ Connect the courtesy lamp. 7. Install the B-pillar trim. 8. Install the lower quarter trim panel. 9. Install the scuff plates 10. In stall the roof side rear trim panels. 11. Install the package tray trim panel. 12. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7839 NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Cable - Isolator Module to FM Antenna REMOVAL 1. Remove the rear package tray trim. 2. Remove the RH roof side rear trim panel. 3. Position sound insulator aside. 4. Disconnect the antenna cable. 5. Position the headliner aside. 1 Remove the pin-type retainers. 2 Position the headliner aside. 6. Remove the antenna lead-in cable. 1 Disconnect the connector. 2 Remove the bolt. 3 Disconnect the cable retainers and remove the antenna lead-in cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 7845 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) Alarm Module: Service and Repair Module - Passive Anti-Theft System (PATS) REMOVAL 1. Disconnect the battery ground cable. CAUTION ^ Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded in to the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH instrument panel insulator. 1 Remove the pin-type retainers. 2 Remove the LH instrument panel insulator. 3. Remove the lower steering column cover. 1 Remove the screws. 2. Remove the lower steering column cover. 4. Remove the lower steering column cover reinforcement 1 Remove the screws. 2 Remove the lower steering column cover reinforcement. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7848 5. Remove the Passive Anti-Theft System (PATS) module and bracket. 1 Remove the bolts. 2 Disconnect the electrical connector. INSTALLATION 1. To install,reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. ^ Prior to starting the vehicle, check for PATS Diagnostic Trouble Codes (DTCs). Perform the appropriate pinpoint test. ^ When the PATS module is replaced, both ignition keys must be relearned and stored in memory. Insert each key in the ignition and turn to RUN for automatic programming. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7849 Alarm Module: Service and Repair Module - Passive Anti-Theft Transceiver REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. NOTE: The steering wheel has been removed for clarity. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7850 5. Remove LH instrument panel insulator. 1 Remove the pin-type retainers. 2 Remove the insulator. 6. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. 7. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 8. Remove the transceiver assembly. 1 Remove the screw. 2 Release the transceiver over the rib on the lock cylinder housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7851 NOTE: Only apply pressure below the key cylinder rib. 3 Disconnect the electrical connector locator and electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. ^ No key replacement or re-initialization needs to occur with the removal or installation of a new PATS transceiver. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 7856 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door panel. 3. Position weathershield aside. 4. Remove the keyless entry keypad. 1 Remove the Clip. ^ Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair 1. Cycle the ignition from OFF to RUN four times within three seconds. The locks will then lock and unlock, confirming program mode has been entered. 2. Press any button on the transmitter to be programmed. NOTE: When the first keyless entry remote transmitter is programmed, all other keyless entry remote transmitters are erased. 3. If additional keyless entry remote transmitters are to be programmed, repeat step 2 within 7.5 seconds. 4. To exit program mode, turn the ignition to START or wait 7.5 seconds. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation The HomeLink(R) universal transmitter provides a convenient way to replace up to three hand-held transmitters with a single built-in device. The universal transmitter: ^ will operate garage doors, gates and home/office lighting and security Systems. ^ will actually learn and transmit the radio frequency of up to three hand-held transmitters from any of the systems mentioned above. ^ is an integral part of the left sun visor assembly and is powered by the vehicle battery and charging system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Flow of Diagnosis Garage Door Opener Transmitter: Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged universal transmitter ^ Damaged receiver 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7865 Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged universal transmitter ^ Damaged receiver 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7866 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7867 A1 - A2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Programming Garage Door Opener Transmitter: Service and Repair Programming WARNING: A GARAGE DOOR OPENING SYSTEM THAT CANNOT STOP OR REVERSE ITSELF AFTER DETECTING AN OBJECT IN ITS PATH DOES NOT MEET CURRENT FEDERAL SAFETY STANDARDS. TO DECREASE THE RISK OF SERIOUS INJURY OR DEATH, DO NOT USE THIS HOMELINK(R) TRANSMITTER WITH A DOOR OPENING SYSTEM THAT LACKS STOP AND REVERSE FEATURES AS REQUIRED BY FEDERAL STANDARDS. THIS INCLUDES ANY GARAGE DOOR OPENING SYSTEM MANUFACTURED BEFORE APRIL 1, 1982. FOR MORE INFORMATION, CALL HOMELINK(R) CUSTOMER ASSISTANCE AT 1-800-355-3515. 1. Verify the hand-held transmitter is operative. CAUTION: During this procedure, the system that you are programming will be made to operate. Make sure that people or objects are clear of the garage door or gate being programmed. 2. Prepare for programming the universal transmitter by erasing all three channels by holding down the two outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. 3. Select one of the three universal transmitter channels to be programmed by pressing the desired button. 4. Hold the end of the hand-held transmitter from the front surface of the universal transmitter so that the red light can still be seen. 5. Use both hands to press the hand-held transmitter button and the desired button on the universal transmitter. Do not release either button. NOTE: During programming, the hand-held transmitter may automatically stop transmitting after two seconds, which may not be long enough to program the universal transmitter. If programming this type of hand-held transmitter, continue to hold the button on the universal transmitter while re-pressing the hand-held transmitter button every two seconds (Canada only). 6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and then rapidly. Release both buttons when the rapid flashing begins. The universal transmitter has successfully learned the new frequency signal and can be used in place of the hand-held transmitter(s). 7. To operate, simply press the appropriate button on the universal transmitter. The red light is on while the signal is being transmitted. NOTE: If the hand-held transmitter appears to program the universal transmitter but does not open the garage door, the garage door opener may have a "code protected" or "rolling code" feature. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Programming > Page 7870 Garage Door Opener Transmitter: Service and Repair Training A Garage Door Opener Equipped With "Rolling Codes" Training a Garage Door Opener Equipped With "Rolling Codes" 1. Program the hand-held transmitter to the universal transmitter. 2. Train the garage door opener receiver to recognize the universal transmitter. 1 Remove the cover panel from the garage door opener receiver. 2 Locate the training button on the garage door opener receiver. Location and color of the button may vary by garage door opener manufacturer. Refer to the garage door opener instruction manual or call HomeLink(R) customer assistance at 1-800-355-3515. 3 Press the training button on the garage door opener receiver for 1-2 seconds. 4 Press the programmed universal transmitter button for as long as the universal transmitter red light flashes (1-2 seconds). Release the button and re-press the button to confirm that the universal transmitter is trained to the receiver. 5 The garage door opener should recognize the universal transmitter. Erasing Channels 1. To erase all three programmed channels, hold down the two outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for programming. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Description and Operation Multifunction Electronic Control Module: Description and Operation The multifunction modules consist of the following: ^ Air Suspension Control Module ^ Driver Door Module (DDM) ^ Lighting Control Module (LCM) The air suspension control module is linked to its own Data Link Connector (DLC). The air suspension control module controls the air suspension and the Electronic Variable Orifice (EVO) steering. The Driver Door Module (DDM) is connected on the International Standards Organization (ISO) 9141 communication network. The DDM controls many functions including power windows, power door locks and remote keyless entry. The Lighting Control Module (LCM) is connected on the ISO 9141 communication network. The LCM controls both interior and exterior lighting, back lighting, the battery saver and warning chimes. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Description and Operation > Page 7874 Multifunction Electronic Control Module: Testing and Inspection For Air Suspension concerns, See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic ) For Electronic Variable Orifice (EVO) Steering concerns, For Warning Chime concerns, See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device For Lighting concerns, See: Lighting and Horns For Power Window or Defroster concerns, See: Windows and Glass For Power Door Lock concerns, See: Antitheft and Alarm Systems/Keyless Entry Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module Multifunction Electronic Control Module: Service and Repair Air Suspension Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Lower the instrument panel lower insulator. 1 Remove the pin-type retainers. 2 Lower the instrument panel lower insulator. 3. Remove the instrument panel lower insulator. 1 Disconnect the power point electrical connector. 2 Remove the footwell lamp. 3 Remove the instrument panel lower insulator. 4. Remove the air suspension module. 1 Disconnect the electrical connectors. 2 Remove the air suspension module. ^ Release the spring clips to remove the module from the bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7877 Multifunction Electronic Control Module: Service and Repair Driver Door Module REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door trim panel. 3. Remove the Driver Door Module (DDM). 1 Disconnect the electrical connector. 2 Remove the screws. 3. Release the locking tab. INSTALLATION CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7878 Multifunction Electronic Control Module: Service and Repair Lighting Control Module REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH instrument panel lower insulator. 1 Remove the pin-type retainers. 2 Disconnect the courtesy lamp. 3 Remove the LH instrument panel insulator. 3. Position the LCM aside. 1 Remove the locking tab. 2 Release the locking tab. 3 Position the LCM aside. 4. Remove the LCM. 1 Disconnect the electrical connectors. 2 Remove the LCM. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7879 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 7888 CD Changer: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. If equipped, position the luggage compartment cover aside. 3. Remove the digital audio compact disc changer. 1 Remove the bolt. 2 Remove the nuts. 3 Disconnect the electrical connector. 4. Remove the digital audio compact disc changer brackets. ^ Remove the six bolts and two brackets. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7898 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7899 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7900 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7901 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7902 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7903 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7904 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7910 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7911 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7912 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7913 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7914 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7915 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7916 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7925 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7926 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7927 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7928 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7929 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7930 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7931 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7937 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7938 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7939 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7940 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7941 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7942 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7943 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 7944 Speaker: Description and Operation There are two speaker Systems available: ^ premium sound system ^ base sound system The premium sound speaker system has one speaker mounted in each front door and two speakers mounted in the package tray. The speakers consist of: ^ radio speaker (rear base and premium) ^ radio speaker (front base and premium) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speaker: Service and Repair Door Mounted REMOVAL 1. Remove the front door trim panels. 2. Remove the radio speakers. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the radio speakers. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted > Page 7947 Speaker: Service and Repair Package Tray Speaker REMOVAL 1. Remove the package tray trim panel. 2. Remove the radio speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the radio speaker from the speaker cover. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair Tape Player: Service and Repair 1. For best performance, it is recommended that the tape player be cleaned once for every 10 to 12 hours of playing time. The tape player should be cleaned using a Ford tape player cleaning cartridge, available at your Ford or Lincoln-Mercury Dealer. The use of other cleaning products is not recommended, as these products could cause damage to the player or cassette tapes. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 7956 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) Alarm Module: Service and Repair Module - Passive Anti-Theft System (PATS) REMOVAL 1. Disconnect the battery ground cable. CAUTION ^ Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded in to the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH instrument panel insulator. 1 Remove the pin-type retainers. 2 Remove the LH instrument panel insulator. 3. Remove the lower steering column cover. 1 Remove the screws. 2. Remove the lower steering column cover. 4. Remove the lower steering column cover reinforcement 1 Remove the screws. 2 Remove the lower steering column cover reinforcement. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7959 5. Remove the Passive Anti-Theft System (PATS) module and bracket. 1 Remove the bolts. 2 Disconnect the electrical connector. INSTALLATION 1. To install,reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. ^ Prior to starting the vehicle, check for PATS Diagnostic Trouble Codes (DTCs). Perform the appropriate pinpoint test. ^ When the PATS module is replaced, both ignition keys must be relearned and stored in memory. Insert each key in the ignition and turn to RUN for automatic programming. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7960 Alarm Module: Service and Repair Module - Passive Anti-Theft Transceiver REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. NOTE: The steering wheel has been removed for clarity. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7961 5. Remove LH instrument panel insulator. 1 Remove the pin-type retainers. 2 Remove the insulator. 6. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. 7. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 8. Remove the transceiver assembly. 1 Remove the screw. 2 Release the transceiver over the rib on the lock cylinder housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7962 NOTE: Only apply pressure below the key cylinder rib. 3 Disconnect the electrical connector locator and electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. ^ No key replacement or re-initialization needs to occur with the removal or installation of a new PATS transceiver. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Description and Operation Multifunction Electronic Control Module: Description and Operation The multifunction modules consist of the following: ^ Air Suspension Control Module ^ Driver Door Module (DDM) ^ Lighting Control Module (LCM) The air suspension control module is linked to its own Data Link Connector (DLC). The air suspension control module controls the air suspension and the Electronic Variable Orifice (EVO) steering. The Driver Door Module (DDM) is connected on the International Standards Organization (ISO) 9141 communication network. The DDM controls many functions including power windows, power door locks and remote keyless entry. The Lighting Control Module (LCM) is connected on the ISO 9141 communication network. The LCM controls both interior and exterior lighting, back lighting, the battery saver and warning chimes. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Description and Operation > Page 7966 Multifunction Electronic Control Module: Testing and Inspection For Air Suspension concerns, See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic ) For Electronic Variable Orifice (EVO) Steering concerns, For Warning Chime concerns, See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device For Lighting concerns, See: Lighting and Horns For Power Window or Defroster concerns, See: Windows and Glass For Power Door Lock concerns, See: Antitheft and Alarm Systems/Keyless Entry Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module Multifunction Electronic Control Module: Service and Repair Air Suspension Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Lower the instrument panel lower insulator. 1 Remove the pin-type retainers. 2 Lower the instrument panel lower insulator. 3. Remove the instrument panel lower insulator. 1 Disconnect the power point electrical connector. 2 Remove the footwell lamp. 3 Remove the instrument panel lower insulator. 4. Remove the air suspension module. 1 Disconnect the electrical connectors. 2 Remove the air suspension module. ^ Release the spring clips to remove the module from the bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7969 Multifunction Electronic Control Module: Service and Repair Driver Door Module REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door trim panel. 3. Remove the Driver Door Module (DDM). 1 Disconnect the electrical connector. 2 Remove the screws. 3. Release the locking tab. INSTALLATION CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7970 Multifunction Electronic Control Module: Service and Repair Lighting Control Module REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH instrument panel lower insulator. 1 Remove the pin-type retainers. 2 Disconnect the courtesy lamp. 3 Remove the LH instrument panel insulator. 3. Position the LCM aside. 1 Remove the locking tab. 2 Release the locking tab. 3 Position the LCM aside. 4. Remove the LCM. 1 Disconnect the electrical connectors. 2 Remove the LCM. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7971 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Release the linkage. 3. Remove the rivets. 4. Remove the door handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the watershield. 3. Remove the screw. 4. Pivot the door latch release handle and remove from the rod. 5. Remove the clip. 6. Disconnect the door lock cylinder rod. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 7983 7. Disconnect the connectors. 8. Disconnect the connector. 9. Remove the rivet. 10. Remove the screws. 11. Remove the door lock actuator from the latch. 12. Remove the door latch. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 7984 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Front Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 7989 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 7990 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 7991 Front Door Panel: Service and Repair Door Panel R&R; Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 7992 Door Panel R&R; Removal 1. Remove window regulator control switch housing by gently prying up, starting at the front. 2. Disconnect all connectors from window regulator control switch housing. 3. Remove inside door handle cup by gently prying at screwdriver slot with a screwdriver. 4. Remove screw directly beneath inside door handle. 5. Remove lower screw retaining front door trim panel to door inner panel. 6. Lift front door trim panel upward and snap out trim panel. 7. Disconnect wire harnesses from door panel as required and remove front door trim panel. Installation 1. Connect wire harnesses to front door trim panel as required. 2. Install front door trim panel by pushing in and down until it snaps into place. 3. Install all self-tapping screws retaining front door trim panel to door inner panel. 4. Install inside door handle cup. 5. Install window regulator control switch housing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Position the watershield out of the way. 1 Remove the speaker. 2 Disconnect the driver door module. 3 Position the watershield out of the way. 3. Remove the bolt. 4. Position the front door glass run front retainer forward. 5. Remove the rivets. CAUTION: Do not attempt to forcibly remove the rivets as damage to the front door window glass will result. NOTE: Before removing rivets, it is necessary to place a suitable block support between the front door window channel bracket and the door outer panel to help stabilize the front door window bracket during rivet removal. - Lower the front door window glass to gain access to the two front door window channel bracket rivets. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 7996 6. Remove the front door window glass. INSTALLATION 1. Position the front door window glass into the door frame. 2. Install two 1/4-inch rivets (use of 1/4-20 x 1 inch screw and washer assemblies and 1/4 inch-20 nut and washer are optional). Tighten the nut (if used) to 13 N.m (10 Lb-Ft). NOTE: Align the front door window glass with the front door window channel bracket, if necessary. 3. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Position the watershield out of the way. 1 Remove the speaker. 2 Remove the driver door module. 3 Position the watershield out of the way. 3. Remove the front door window glass. 4. Disconnect the connector. 5. Remove the rivets. 6. Remove the Torx (R) screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 8000 7. Remove the nuts. 8. Remove the regulator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2 Release the linkage. 3. Remove the rivets. 4. Remove the handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the watershield. 3. Remove the screw. 4. Pivot the door latch release handle and remove from the rod. 5. Remove the rivet. 6. Release the lock rod from the clip. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 8009 7. Remove the clip. 8. Disconnect the connectors. 9. Disconnect the connector. 10. Remove the rivet. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 8010 11. Remove the screws. 12. Remove the door latch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Rear Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8015 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8016 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Page 8017 Rear Door Panel: Service and Repair Door Panel R&R; Door Panel R&R; Removal 1. Remove one screw from lower rear door panel. 2. Remove window regulator switch housing by gently prying up, starting at front. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Page 8018 3. Disconnect all electrical connectors from window regulator control switch housing. 4. Remove inside door handle cup by gently prying at screwdriver slot. 5. Remove screw directly below release handle. 6. Lift rear door trim panel upward and snap out trim panel. 7. Disconnect any electrical switches if equipped, and remove rear door trim panel. Installation 1. Follow Removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the pull strap handle. 3. Remove the watershield. 4. Remove the bolt. 5. Remove the rivets. CAUTION: Do not attempt to forcibly remove the rivets as damage to the rear door window glass may result prior to removing the rivet center pins, it is necessary to place a suitable block support between the door outer panel and the rear door window channel bracket to stabilize the rear door window glass during rivet removal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 8022 6. Remove the bolt. 7. Remove the rear door window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Upper Regulator Mounting Nuts 12 Nm Rear Door Window Regulator Motor Screws 6 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 8026 Rear Door Window Regulator: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the pull strap handle. 3. Remove the watershield. 4. Remove the rear door window glass. 5. Disconnect the connector. 6. Remove the rivets. 7. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 8027 8. Remove the rear door window regulator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Switch > Component Information > Description and Operation Fuel Door Lock Switch: Description and Operation The fuel filler door lock switch: - actuates a solenoid integral to the fuel filler door latch to release the fuel filler door. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8043 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8044 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8045 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8046 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8047 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking Technical Service Bulletin # 99B09 Date: 990401 Campaign - Rear Frame Cosmetic Cracking 99B09 OWNER NOTIFICATION PROGRAM Certain 1998-1999 Ford Crown Victoria Police Interceptor, Taxi Cab, & Natural Gas Vehicles (NGV) & Lincoln Town Car Limousine Prep Package & Livery Vehicles Registered in the State of NY Commercial Vehicle Frame Service ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8056 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8057 Attachment I - Administrative Information OASIS OASIS will be activated for this program; however, only vehicles built on or before March 25, 1999 will be active in OASIS until a production action is incorporated. A supplement will be sent (estimated July, 1999) to all dealers when the remaining vehicles have been added to OASIS. If a vehicle, registered in New York but not listed in OASIS, is presented for service in that state and has the same package content and build dates as the "affected vehicles" described in this bulletin, dealers are to call 1-800-325-5621 and provide Ford Motor Company with a description of the concern, VIN, model year and mileage. If this information meets the requirements in this bulletin and the customer is willing to provide needed information, approval to perform repairs and submit a claim will be given by the Recall Hotline. PLEASE NOTE Correct all vehicles in stock before delivery. CLAIMS Enter claims using DWE. See ACESII Manual. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of rear frame cracks at the upper control arm access hole made before date of the Owner Letter enter using DWE: Attachment II - Labor and Parts Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8058 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 99B09 ^ Labor Operation: See above See ACESII manual for detailed instructions. Attachment III - Technical Information AFFECTED VEHICLE: 1998 AND 1999 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR (LIMO, LIVERY) SERVICE PROCEDURE 1. Record radio stations. 2. Disconnect battery negative cable. 3. Raise vehicle on hoist and remove rear wheels. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8059 4. Check to verify torque on both rear suspension upper arm pivot frame bolts is at minimum of 128 Nm (95 lb-ft). Refer to appropriate Service Repair Manual for proper bolt tightening procedure. Refer to Figure 1. 5. Cut off portion of RH flag nut's "flag" that protrudes from frame. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8060 6. Unclip ABS sensor wire from frame and position aside. Refer to Figure 2. 7. If equipped with air spring, wrap air spring in welding blanket. 8. CAUTION: If a crack is found, grind only enough metal away to form the V groove. Do not grind completely through frame parent metal. If frame is cracked, grind a V groove in crack, then remove E coat from around crack. Mig weld the groove using standard mig welding procedures. See Figure 2 for location of mig welder grounding clamp. 9. CAUTION: Only remove paint and any weld material that interferes with reinforcement plate fit. Do not grind frame parent metal. Prep the frame by removing any paint in the affected area. Grind only the welds that will interfere with the reinforcement plate sitting flush to the frame (plate must not "rock"). After grinding, position the plate to check that it sits flush and if necessary, strike any weld with a punch and hammer to deflect the metal enough to allow proper fit. 10. NOTE: Reinforcement plate is properly positioned when the entire access hole is covered and the rear edge is no more than 10 mm (approximately 3/8 in.) from the "lance" on the frame. If necessary, verify proper positioning by close inspection using a shop light. Refer to Figure 2. Position and clamp reinforcement plate onto frame completely covering access hole. 11. CAUTION: Burn-through is not permitted. If any burn-through occurs, the hole must be filled. Using standard mig welding procedures, tack weld reinforcement plate to frame on the two (2) outboard corners, then proceed to weld the perimeter of the reinforcement plate in sequence shown in Figure 2. 12. Remove weld blankets, if previously installed. 13. Spray undercoating on plate and welds being careful to avoid any overspray. 14. Reclip ABS sensor wire. 15. Repeat steps 6 through 14 for other side. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8061 16. Install tires. Tighten lug nuts to 129 Nm (95 lb-ft). Lower hoist. 17. Connect battery negative cable. 18. Program radio stations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8062 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking Technical Service Bulletin # 04-4-1 Date: 040308 Frame - Rear Frame Side Member Cracking Article No. 04-4-1 03/08/04 ^ CHASSIS - FRAME CRACKING - SERVICE PROCEDURE ^ SUSPENSION - FRAME CRACKING - SERVICE PROCEDURE FORD: 1998-2002 CROWN VICTORIA ISSUE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8068 Some 1998-2002 Crown Victoria vehicles used for heavy-duty type service (Police/Taxi/Limo) may exhibit cracks in the rear of the frame side member between the upper and lower trailing arm brackets, or around the opening to the lower trailing arm bracket access hole for the flag nut in the bottom of the frame. These cracks may result from driving events that place extreme stress on the frame (i.e. rear vehicle impact, driving over curbs, high speed through driveway transitions, becoming airborne etc...). Refer to Figures 1, 2 and 3 for examples of cracks. ACTION To service, perform the following procedures to repair the cracks and reinforce the frame. NOTE READ THESE REPAIR INSTRUCTIONS IN THEIR ENTIRETY BEFORE BEGINNING ANY REPAIR. NOTE INSPECT THE VEHICLE FOR COLLISION OR ABUSE-RELATED DAMAGE THAT WOULD HINDER THIS SERVICE PROCEDURE. NOTE ONE KIT WILL REPAIR ONE SIDE OF THE FRAME. IF THE CONDITION IS OBSERVED ON BOTH SIDES OF THE VEHICLE'S FRAME, THEN TWO (2) KITS WILL BE REQUIRED. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8069 NOTE EACH KIT IS EQUIPPED WITH TW6 (2) REINFORCEMENT PLATES, ONE (1) FOR THE LEFT AND ONE (1) FOR THE 'RIGHT HAND SIDE OF THE FRAME. AT THE END OF THE REPAIR, ONE (1) OF THE REINFORCEMENTS FROM EACH KIT WILL BE LEFT OVER. (EXAMPLE: IF A KIT IS USED TO FIX THE RIGHT HAND SIDE OF THE FRAME, THERE WILL BE A LEFT HAND REINFORCEMENT BRACKET LEFT OVER AFTER THE REPAIRS ARE COMPLETED, AND VICE VERSA). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 040401A Repair Cracks In One 4.2 Hrs. Frame Rail Then Install Reinforcement Plates And Structural Foam 040401B Repair Cracks In Both 4.5 Hrs. Frame Rails Then Install Reinforcement Plates And Structural Foam DEALER CODING CONDITION BASIC PART NO. CODE 5B118 01 Disclaimer Service Procedure NOTE PERFORM THE FOLLOWING PROCEDURES AS NECESSARY TO REPAIR CRACKS AND REINFORCE ONE OR BOTH SIDES OF THE FRAME. IT SHOULD BE NOTED THAT IF THE VEHICLE IS SUBJECTED TO A HIGH STRESS EVENT AGAIN, NEW CRACKS MIGHT APPEAR IN THAT AREA. CAUTION ALWAYS DISCONNECT THE BATTERY GROUND CABLE PER WORKSHOP MANUAL SECTION 414-01 BEFORE USING ANY ELECTRICAL WELDING EQUIPMENT. USE ONLY MIG ER-70-56 WIRE WHEN WELDING. REAR FRAME AND BODY SPLIT NOTE DO NOT PERFORM THIS PROCEDURE IF THERE IS NO CRACK ON THE TOP SURFACE OF THE FRAME. In this procedure the bumper cover will be loosened to prevent damage to the cover when the body of the vehicle is lifted away from the vehicle frame. The frame will be split from the body to provide clearance necessary to repair cracks on the top of the vehicle frame. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8070 1. Position the vehicle on a hoist making sure there is adequate access to the body mount bolts (Figure 4) and the lower trailing arm flag nut access hole (see Workshop Manual Section 100-02). 2. Open the hood and disconnect the battery per Workshop Manual Section 414-01. 3. Open the trunk. 4. Remove/place aside the trunk trim on the sides and remove the four (4) rear bumper cover nuts in the trunk (two (2) on each side) (Figure 5 shows left hand side). NOTE IT IS NOT NECESSARY TO REMOVE THE LUGGAGE COMPARTMENT REAR TRIM PANEL. 5. Raise the vehicle to chest height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8071 6. Remove the rear wheels. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8072 7. Remove the rear bumper cover screws from under the bumper fascia rear lip (two (2) or three (3) screws), (Figure 6) and the push pin type retainers from bottom sides of bumper cover (two (2) or three (3) on each side) (Figure 7), six (6) push pin-type retainers (three (3) on each side) in the wheel well at the leading edge of the bumper (Figure 8). 8. Remove the # 2, 3, 4, 5, and 6 body mount bolts on both sides. Refer to (Figure 4) for locations of body mount bolts. NOTE THE # 4 BODY MOUNT BOLTS ARE NEAR THE SPRING SEAT. 9. Install a 2X6 block of wood and two (2) jackscrews up tight against the body between the body drain plugs, partially under the trunk and the fuel tank (Figure 9). 10. It present, unclip the ground strap from the # 6 body holes on the frame on the right and left hand sides. The ground straps are located between the # 6 body hole and the rear cross member. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8073 NOTE DURING STEP 11, WATCH THE BUMPER COVER TO MAKE SURE IT DOES NOT HANG UP ON THE BUMPER REINFORCEMENT BAR. IF IT HANGS UP, THE BUMPER COVER MAY BE DAMAGED. 11. With the jackscrews and wood supporting the weight of the rear of the body, SLOWLY lower the lift so that the body splits from the frame. It will be necessary to create about a 12.7 cm (5") air gap between the frame and the body, at the # 5 body mounts location. Insert a 11.5 to 12.7 mm (4.5" to 5") tall block of 4X4 wood between the frame and the body mounts at the # 5 body mount location on both sides of the vehicle. The block will be flush to the cage nut reinforcement (Figure 10). 12. Raise the hoist and remove the jackscrews. REPAIR OF FRAME CRACKS BETWEEN THE UPPER AND LOWER TRAILING ARM MOUNTING BRACKETS NOTE REFER TO (FIGURES 1 AND 2) FOR THE TYPICAL LOCATION OF THE CRACKS. DO NOT PERFORM THIS PROCEDURE IF CRACKS ARE NOT PRESENT ON THE SIDE RAIL BETWEEN THE UPPER AND LOWER TRAILING ARM BRACKETS. NOTE PERFORM THIS REPAIR ON BOTH SIDES OF THE FRAME IF NECESSARY. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8074 1. If necessary, bend the spot-welded flange at the bottom edge of the inner fender well for improved access~to the frame crack (Figure 11). 2. On the left side only, remove the brake line clip and reposition the line away from welding area. 3. Use an angle grinder to clean off paint and dress the weld area. 4. Weld crack as necessary. 5. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to all weld repair areas. 6. Replace the brake line. 7. Re-bend weld flange into place. LOWER TRAILING ARM MOUNTING NUT ACCESS HOLE OPENING REPAIR AND/OR REINFORCEMENT In this procedure any cracks in the frame area around the lower trailing arm flag nut access hole opening will be repaired. A metal blocker baffle (4W73-4A145-AA) will be inserted into the side rail, and a reinforcement plate (4W73-5A123-AA or 4W73-5A124-M) will be welded to the bottom rail of the frame to close the access hole to strengthen that section hole. NOTE THE BLOCKER BAFFLE WILL PREVENT LEAKAGE OF THE STRUCTURAL FOAM, WHICH WILL BE INTRODUCED INTO THE FRAME. 1. Partially raise the vehicle and locate the access hole for the lower trailing arm. This access hole is located on the bottom of the frame, directly under the lower trailing arm mounting bracket. Inspect for cracks at the lower trailing arm access hole (Figure 3). If cracks are present repair them as necessary. 2. Use an angle grinder to clean off paint and dress the weld area. 3. Weld crack as necessary. 4. Bend two (2) metal Blocker Baffles (one (1) for each side) (4W73-5A145-M) along the crease on the middle of the part. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8075 5. Insert the baffle into the access hole with the narrow end facing upwards. Minimize bending the flanges. The blocker baffle will prevent the structural foam from running out of the frame and/or covering the trailing arm nut. The flanges should face the front of the car (Figure 12). 6. Once inside the rail section, unbend and position the blocker baffle to get a tight seal to the frame rail section. Perform one of the following procedures: a. On the left hand side bracket, line up the bottom edge of the blocker baffle flange to the rear edge of the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the top rear weld on the lower trailing arm bracket. Inspect the blocker baffle for a good seal between the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of the blocker baffle to improve seal between the blocker baffle and the frame. The flag nut may need to be bent out of the way to accommodate the blocker baffle. Tack weld the blocker baffle. b. On the right hand side bracket, line up the vertical face of the blocker baffle to the rear edge of the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the top rear weld on the lower trailing arm bracket (Figure 12). Inspect the blocker baffle for a good seal between the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of the blocker baffle to improve seal between the blocker baffle and the frame. Tack weld the blocker baffle. 7. Grind the area around the access hole in the bottom of the frame at the trailing arm, including any welds that may have been added to repair Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8076 cracks. Grind any welds where needed for proper location of the reinforcement patch (Figure 13). Do not grind away the parent metal. The reinforcement plate must be located flush to the frame. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8077 8. Center the slot of Reinforcement Patch (4W73-5A123-AA right hand side marked "R") or 4W73-5A124-M left hand side (marked "L") to the center of the trailing arm bolt taking care that the frame rail does not overlap the slot (Figure 14). Tack in place, then weld around the reinforcement plate completely (Figure 15 and 16). REINFORCE FRAME WITH STRUCTURAL FOAM In this procedure the frame rail section will be reinforced with Motorcraft Structural Foam that will add strength to the frame and reduce the potential for cracks in the frame in the area. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8078 1. Clean around the tooling hole and all other holes in the area on the frame rail located between the upper and lower trailing arm-mounting brackets (Figure 17 and 18). 2. Apply duct tape over the holes. 3. Pierce a 6 mm (1/4") hole into the duct tape covering the outer tooling hole to allow easy introduction of the nozzle into the tooling hole through the tape (Figure 19). 4. Lower the vehicle to chest height. NOTE IT IS SUGGESTED THAT GLOVES BE WORN WHEN WORKING THE HEATED TUBES OF MOTORCRAFT STRUCTURAL FOAM AS OUTLINED IN STEPS 5 THROUGH 7. ADDITIONALLY, THE STRUCTURAL FOAM WILL CAUSE THE SIDE MEMBER SURFACE TO BECOME VERY WARM AS A RESULT OF THE CHEMICAL REACTION. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8079 5. Put the five (5) tubes of 1U2J-19554-DA Motorcraft Structural Foam on a table and heat the tubes front and back with a heat gun to approximately 71.1 °C (160 °F). This will help soften the two parts of the Structural Foam so that it will flow out of the tubes and through the mixing wand easily (Figure 20). 6. Remove the small black plugs from a tube of structural foam. Install the nozzle (4W73-19H255-M) and replace the holding nuts. Balance the plungers by gunning out some material. Ensure that it comes out from both tubes. Press the tab on the back of the gun to relieve pressure. This will prevent the foam from streaming out of the tube uncontrollably. 7. Insert the nozzle through the hole cut into the duct tape in the outside tooling hole (Figure 19). Pump the tube of Structural Foam into the frame rail. When the Structural Foam rises to the height of the tooling hole, it will be necessary to duct tape the hole when switching tubes to prevent leakage of the Structural Foam. NOTE REPEAT STEPS 6-7 UNTIL ALL FIVE (5) TUBES OF 1U2J-19554-DA MOTORCRAFT STRUCTURAL FOAM HAVE BEEN PUMPED INTO THE FRAME. ALLOW AT LEAST THIRTY (30) MINUTES FOR THE STRUCTURAL FOAM TO CURE BEFORE REMOVING THE DUCT TAPE. 8. Raise the vehicle all the way up. 9. Remove duct tape. 10. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to the weld areas. REASSEMBLE FRAME AND BODY In the following steps the frame will be reassembled to the body, and the bumper fascia will be reinstalled. NOTE REQUIRED ONLY IF THE "REAR FRAME AND BODY SPLIT" PROCEDURE WAS PERFORMED. 1. Partially raise the vehicle. 2. Reinstall a 2X6 block of wood and two (2) jackscrews up tight against the body between the body drain plugs, partially under the trunk and the fuel tank (Figure 9). 3. Lower the hoist until the 2X6 block fits snug against the body. 4. Remove the wood block between the frame and the body mounts at the # 5 body mount location on each side of the vehicle (Figure 10). It may be necessary to further lower the hoist by 6 to 12 mm (1/4" to 1/2"). 5. SLOWLY raise the hoist until the frame is off the jackscrews and is flush with the body. Watch the bumper cover to make sure that it does not Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8080 become damaged. 6. Remove the jackscrews and the 2X6 block from under the vehicle. 7. Clip the ground strap to the #6 body holes on the frame on the right and left hand. 8. Reinstall the # 2, 3, 4, 5, and 6 body mount bolts on both sides. 9. Torque bolts to 48-50 N.m (35.4-36.8 lb-ft). 10. Partially lower the vehicle to waist height. 11. Relocate the bumper fascia and four (4) bumper cover nuts (two (2) on each side). 12. Torque bolts to 7 N.m (61.9 lb-in) (Figure 3 shows left hand side). 13. Reposition trunk trim sides. 14. Partially raise the vehicle. 15. Replace the six (6) pin-type retainers (three (3) on each side) in the wheel well leading edge of the bumper (Figure 8) and the push pin-type retainers (two (2) or three (3) on each side) from bottom sides of bumper cover (Figure 7). 16. Partially lower the vehicle. 17. Replace the rear wheel and tire assemblies. 18. Lower the hoist. 19. Close the trunk. 20. Reconnect the battery per Workshop Manual: Section 414-01. 21. Close the hood. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking Technical Service Bulletin # 04-4-1 Date: 040308 Frame - Rear Frame Side Member Cracking Article No. 04-4-1 03/08/04 ^ CHASSIS - FRAME CRACKING - SERVICE PROCEDURE ^ SUSPENSION - FRAME CRACKING - SERVICE PROCEDURE FORD: 1998-2002 CROWN VICTORIA ISSUE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8086 Some 1998-2002 Crown Victoria vehicles used for heavy-duty type service (Police/Taxi/Limo) may exhibit cracks in the rear of the frame side member between the upper and lower trailing arm brackets, or around the opening to the lower trailing arm bracket access hole for the flag nut in the bottom of the frame. These cracks may result from driving events that place extreme stress on the frame (i.e. rear vehicle impact, driving over curbs, high speed through driveway transitions, becoming airborne etc...). Refer to Figures 1, 2 and 3 for examples of cracks. ACTION To service, perform the following procedures to repair the cracks and reinforce the frame. NOTE READ THESE REPAIR INSTRUCTIONS IN THEIR ENTIRETY BEFORE BEGINNING ANY REPAIR. NOTE INSPECT THE VEHICLE FOR COLLISION OR ABUSE-RELATED DAMAGE THAT WOULD HINDER THIS SERVICE PROCEDURE. NOTE ONE KIT WILL REPAIR ONE SIDE OF THE FRAME. IF THE CONDITION IS OBSERVED ON BOTH SIDES OF THE VEHICLE'S FRAME, THEN TWO (2) KITS WILL BE REQUIRED. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8087 NOTE EACH KIT IS EQUIPPED WITH TW6 (2) REINFORCEMENT PLATES, ONE (1) FOR THE LEFT AND ONE (1) FOR THE 'RIGHT HAND SIDE OF THE FRAME. AT THE END OF THE REPAIR, ONE (1) OF THE REINFORCEMENTS FROM EACH KIT WILL BE LEFT OVER. (EXAMPLE: IF A KIT IS USED TO FIX THE RIGHT HAND SIDE OF THE FRAME, THERE WILL BE A LEFT HAND REINFORCEMENT BRACKET LEFT OVER AFTER THE REPAIRS ARE COMPLETED, AND VICE VERSA). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 040401A Repair Cracks In One 4.2 Hrs. Frame Rail Then Install Reinforcement Plates And Structural Foam 040401B Repair Cracks In Both 4.5 Hrs. Frame Rails Then Install Reinforcement Plates And Structural Foam DEALER CODING CONDITION BASIC PART NO. CODE 5B118 01 Disclaimer Service Procedure NOTE PERFORM THE FOLLOWING PROCEDURES AS NECESSARY TO REPAIR CRACKS AND REINFORCE ONE OR BOTH SIDES OF THE FRAME. IT SHOULD BE NOTED THAT IF THE VEHICLE IS SUBJECTED TO A HIGH STRESS EVENT AGAIN, NEW CRACKS MIGHT APPEAR IN THAT AREA. CAUTION ALWAYS DISCONNECT THE BATTERY GROUND CABLE PER WORKSHOP MANUAL SECTION 414-01 BEFORE USING ANY ELECTRICAL WELDING EQUIPMENT. USE ONLY MIG ER-70-56 WIRE WHEN WELDING. REAR FRAME AND BODY SPLIT NOTE DO NOT PERFORM THIS PROCEDURE IF THERE IS NO CRACK ON THE TOP SURFACE OF THE FRAME. In this procedure the bumper cover will be loosened to prevent damage to the cover when the body of the vehicle is lifted away from the vehicle frame. The frame will be split from the body to provide clearance necessary to repair cracks on the top of the vehicle frame. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8088 1. Position the vehicle on a hoist making sure there is adequate access to the body mount bolts (Figure 4) and the lower trailing arm flag nut access hole (see Workshop Manual Section 100-02). 2. Open the hood and disconnect the battery per Workshop Manual Section 414-01. 3. Open the trunk. 4. Remove/place aside the trunk trim on the sides and remove the four (4) rear bumper cover nuts in the trunk (two (2) on each side) (Figure 5 shows left hand side). NOTE IT IS NOT NECESSARY TO REMOVE THE LUGGAGE COMPARTMENT REAR TRIM PANEL. 5. Raise the vehicle to chest height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8089 6. Remove the rear wheels. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8090 7. Remove the rear bumper cover screws from under the bumper fascia rear lip (two (2) or three (3) screws), (Figure 6) and the push pin type retainers from bottom sides of bumper cover (two (2) or three (3) on each side) (Figure 7), six (6) push pin-type retainers (three (3) on each side) in the wheel well at the leading edge of the bumper (Figure 8). 8. Remove the # 2, 3, 4, 5, and 6 body mount bolts on both sides. Refer to (Figure 4) for locations of body mount bolts. NOTE THE # 4 BODY MOUNT BOLTS ARE NEAR THE SPRING SEAT. 9. Install a 2X6 block of wood and two (2) jackscrews up tight against the body between the body drain plugs, partially under the trunk and the fuel tank (Figure 9). 10. It present, unclip the ground strap from the # 6 body holes on the frame on the right and left hand sides. The ground straps are located between the # 6 body hole and the rear cross member. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8091 NOTE DURING STEP 11, WATCH THE BUMPER COVER TO MAKE SURE IT DOES NOT HANG UP ON THE BUMPER REINFORCEMENT BAR. IF IT HANGS UP, THE BUMPER COVER MAY BE DAMAGED. 11. With the jackscrews and wood supporting the weight of the rear of the body, SLOWLY lower the lift so that the body splits from the frame. It will be necessary to create about a 12.7 cm (5") air gap between the frame and the body, at the # 5 body mounts location. Insert a 11.5 to 12.7 mm (4.5" to 5") tall block of 4X4 wood between the frame and the body mounts at the # 5 body mount location on both sides of the vehicle. The block will be flush to the cage nut reinforcement (Figure 10). 12. Raise the hoist and remove the jackscrews. REPAIR OF FRAME CRACKS BETWEEN THE UPPER AND LOWER TRAILING ARM MOUNTING BRACKETS NOTE REFER TO (FIGURES 1 AND 2) FOR THE TYPICAL LOCATION OF THE CRACKS. DO NOT PERFORM THIS PROCEDURE IF CRACKS ARE NOT PRESENT ON THE SIDE RAIL BETWEEN THE UPPER AND LOWER TRAILING ARM BRACKETS. NOTE PERFORM THIS REPAIR ON BOTH SIDES OF THE FRAME IF NECESSARY. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8092 1. If necessary, bend the spot-welded flange at the bottom edge of the inner fender well for improved access~to the frame crack (Figure 11). 2. On the left side only, remove the brake line clip and reposition the line away from welding area. 3. Use an angle grinder to clean off paint and dress the weld area. 4. Weld crack as necessary. 5. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to all weld repair areas. 6. Replace the brake line. 7. Re-bend weld flange into place. LOWER TRAILING ARM MOUNTING NUT ACCESS HOLE OPENING REPAIR AND/OR REINFORCEMENT In this procedure any cracks in the frame area around the lower trailing arm flag nut access hole opening will be repaired. A metal blocker baffle (4W73-4A145-AA) will be inserted into the side rail, and a reinforcement plate (4W73-5A123-AA or 4W73-5A124-M) will be welded to the bottom rail of the frame to close the access hole to strengthen that section hole. NOTE THE BLOCKER BAFFLE WILL PREVENT LEAKAGE OF THE STRUCTURAL FOAM, WHICH WILL BE INTRODUCED INTO THE FRAME. 1. Partially raise the vehicle and locate the access hole for the lower trailing arm. This access hole is located on the bottom of the frame, directly under the lower trailing arm mounting bracket. Inspect for cracks at the lower trailing arm access hole (Figure 3). If cracks are present repair them as necessary. 2. Use an angle grinder to clean off paint and dress the weld area. 3. Weld crack as necessary. 4. Bend two (2) metal Blocker Baffles (one (1) for each side) (4W73-5A145-M) along the crease on the middle of the part. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8093 5. Insert the baffle into the access hole with the narrow end facing upwards. Minimize bending the flanges. The blocker baffle will prevent the structural foam from running out of the frame and/or covering the trailing arm nut. The flanges should face the front of the car (Figure 12). 6. Once inside the rail section, unbend and position the blocker baffle to get a tight seal to the frame rail section. Perform one of the following procedures: a. On the left hand side bracket, line up the bottom edge of the blocker baffle flange to the rear edge of the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the top rear weld on the lower trailing arm bracket. Inspect the blocker baffle for a good seal between the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of the blocker baffle to improve seal between the blocker baffle and the frame. The flag nut may need to be bent out of the way to accommodate the blocker baffle. Tack weld the blocker baffle. b. On the right hand side bracket, line up the vertical face of the blocker baffle to the rear edge of the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the top rear weld on the lower trailing arm bracket (Figure 12). Inspect the blocker baffle for a good seal between the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of the blocker baffle to improve seal between the blocker baffle and the frame. Tack weld the blocker baffle. 7. Grind the area around the access hole in the bottom of the frame at the trailing arm, including any welds that may have been added to repair Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8094 cracks. Grind any welds where needed for proper location of the reinforcement patch (Figure 13). Do not grind away the parent metal. The reinforcement plate must be located flush to the frame. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8095 8. Center the slot of Reinforcement Patch (4W73-5A123-AA right hand side marked "R") or 4W73-5A124-M left hand side (marked "L") to the center of the trailing arm bolt taking care that the frame rail does not overlap the slot (Figure 14). Tack in place, then weld around the reinforcement plate completely (Figure 15 and 16). REINFORCE FRAME WITH STRUCTURAL FOAM In this procedure the frame rail section will be reinforced with Motorcraft Structural Foam that will add strength to the frame and reduce the potential for cracks in the frame in the area. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8096 1. Clean around the tooling hole and all other holes in the area on the frame rail located between the upper and lower trailing arm-mounting brackets (Figure 17 and 18). 2. Apply duct tape over the holes. 3. Pierce a 6 mm (1/4") hole into the duct tape covering the outer tooling hole to allow easy introduction of the nozzle into the tooling hole through the tape (Figure 19). 4. Lower the vehicle to chest height. NOTE IT IS SUGGESTED THAT GLOVES BE WORN WHEN WORKING THE HEATED TUBES OF MOTORCRAFT STRUCTURAL FOAM AS OUTLINED IN STEPS 5 THROUGH 7. ADDITIONALLY, THE STRUCTURAL FOAM WILL CAUSE THE SIDE MEMBER SURFACE TO BECOME VERY WARM AS A RESULT OF THE CHEMICAL REACTION. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8097 5. Put the five (5) tubes of 1U2J-19554-DA Motorcraft Structural Foam on a table and heat the tubes front and back with a heat gun to approximately 71.1 °C (160 °F). This will help soften the two parts of the Structural Foam so that it will flow out of the tubes and through the mixing wand easily (Figure 20). 6. Remove the small black plugs from a tube of structural foam. Install the nozzle (4W73-19H255-M) and replace the holding nuts. Balance the plungers by gunning out some material. Ensure that it comes out from both tubes. Press the tab on the back of the gun to relieve pressure. This will prevent the foam from streaming out of the tube uncontrollably. 7. Insert the nozzle through the hole cut into the duct tape in the outside tooling hole (Figure 19). Pump the tube of Structural Foam into the frame rail. When the Structural Foam rises to the height of the tooling hole, it will be necessary to duct tape the hole when switching tubes to prevent leakage of the Structural Foam. NOTE REPEAT STEPS 6-7 UNTIL ALL FIVE (5) TUBES OF 1U2J-19554-DA MOTORCRAFT STRUCTURAL FOAM HAVE BEEN PUMPED INTO THE FRAME. ALLOW AT LEAST THIRTY (30) MINUTES FOR THE STRUCTURAL FOAM TO CURE BEFORE REMOVING THE DUCT TAPE. 8. Raise the vehicle all the way up. 9. Remove duct tape. 10. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to the weld areas. REASSEMBLE FRAME AND BODY In the following steps the frame will be reassembled to the body, and the bumper fascia will be reinstalled. NOTE REQUIRED ONLY IF THE "REAR FRAME AND BODY SPLIT" PROCEDURE WAS PERFORMED. 1. Partially raise the vehicle. 2. Reinstall a 2X6 block of wood and two (2) jackscrews up tight against the body between the body drain plugs, partially under the trunk and the fuel tank (Figure 9). 3. Lower the hoist until the 2X6 block fits snug against the body. 4. Remove the wood block between the frame and the body mounts at the # 5 body mount location on each side of the vehicle (Figure 10). It may be necessary to further lower the hoist by 6 to 12 mm (1/4" to 1/2"). 5. SLOWLY raise the hoist until the frame is off the jackscrews and is flush with the body. Watch the bumper cover to make sure that it does not Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8098 become damaged. 6. Remove the jackscrews and the 2X6 block from under the vehicle. 7. Clip the ground strap to the #6 body holes on the frame on the right and left hand. 8. Reinstall the # 2, 3, 4, 5, and 6 body mount bolts on both sides. 9. Torque bolts to 48-50 N.m (35.4-36.8 lb-ft). 10. Partially lower the vehicle to waist height. 11. Relocate the bumper fascia and four (4) bumper cover nuts (two (2) on each side). 12. Torque bolts to 7 N.m (61.9 lb-in) (Figure 3 shows left hand side). 13. Reposition trunk trim sides. 14. Partially raise the vehicle. 15. Replace the six (6) pin-type retainers (three (3) on each side) in the wheel well leading edge of the bumper (Figure 8) and the push pin-type retainers (two (2) or three (3) on each side) from bottom sides of bumper cover (Figure 7). 16. Partially lower the vehicle. 17. Replace the rear wheel and tire assemblies. 18. Lower the hoist. 19. Close the trunk. 20. Reconnect the battery per Workshop Manual: Section 414-01. 21. Close the hood. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking Technical Service Bulletin # 99B09 Date: 990401 Campaign - Rear Frame Cosmetic Cracking 99B09 OWNER NOTIFICATION PROGRAM Certain 1998-1999 Ford Crown Victoria Police Interceptor, Taxi Cab, & Natural Gas Vehicles (NGV) & Lincoln Town Car Limousine Prep Package & Livery Vehicles Registered in the State of NY Commercial Vehicle Frame Service ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8103 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8104 Attachment I - Administrative Information OASIS OASIS will be activated for this program; however, only vehicles built on or before March 25, 1999 will be active in OASIS until a production action is incorporated. A supplement will be sent (estimated July, 1999) to all dealers when the remaining vehicles have been added to OASIS. If a vehicle, registered in New York but not listed in OASIS, is presented for service in that state and has the same package content and build dates as the "affected vehicles" described in this bulletin, dealers are to call 1-800-325-5621 and provide Ford Motor Company with a description of the concern, VIN, model year and mileage. If this information meets the requirements in this bulletin and the customer is willing to provide needed information, approval to perform repairs and submit a claim will be given by the Recall Hotline. PLEASE NOTE Correct all vehicles in stock before delivery. CLAIMS Enter claims using DWE. See ACESII Manual. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of rear frame cracks at the upper control arm access hole made before date of the Owner Letter enter using DWE: Attachment II - Labor and Parts Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8105 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 99B09 ^ Labor Operation: See above See ACESII manual for detailed instructions. Attachment III - Technical Information AFFECTED VEHICLE: 1998 AND 1999 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR (LIMO, LIVERY) SERVICE PROCEDURE 1. Record radio stations. 2. Disconnect battery negative cable. 3. Raise vehicle on hoist and remove rear wheels. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8106 4. Check to verify torque on both rear suspension upper arm pivot frame bolts is at minimum of 128 Nm (95 lb-ft). Refer to appropriate Service Repair Manual for proper bolt tightening procedure. Refer to Figure 1. 5. Cut off portion of RH flag nut's "flag" that protrudes from frame. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8107 6. Unclip ABS sensor wire from frame and position aside. Refer to Figure 2. 7. If equipped with air spring, wrap air spring in welding blanket. 8. CAUTION: If a crack is found, grind only enough metal away to form the V groove. Do not grind completely through frame parent metal. If frame is cracked, grind a V groove in crack, then remove E coat from around crack. Mig weld the groove using standard mig welding procedures. See Figure 2 for location of mig welder grounding clamp. 9. CAUTION: Only remove paint and any weld material that interferes with reinforcement plate fit. Do not grind frame parent metal. Prep the frame by removing any paint in the affected area. Grind only the welds that will interfere with the reinforcement plate sitting flush to the frame (plate must not "rock"). After grinding, position the plate to check that it sits flush and if necessary, strike any weld with a punch and hammer to deflect the metal enough to allow proper fit. 10. NOTE: Reinforcement plate is properly positioned when the entire access hole is covered and the rear edge is no more than 10 mm (approximately 3/8 in.) from the "lance" on the frame. If necessary, verify proper positioning by close inspection using a shop light. Refer to Figure 2. Position and clamp reinforcement plate onto frame completely covering access hole. 11. CAUTION: Burn-through is not permitted. If any burn-through occurs, the hole must be filled. Using standard mig welding procedures, tack weld reinforcement plate to frame on the two (2) outboard corners, then proceed to weld the perimeter of the reinforcement plate in sequence shown in Figure 2. 12. Remove weld blankets, if previously installed. 13. Spray undercoating on plate and welds being careful to avoid any overspray. 14. Reclip ABS sensor wire. 15. Repeat steps 6 through 14 for other side. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8108 16. Install tires. Tighten lug nuts to 129 Nm (95 lb-ft). Lower hoist. 17. Connect battery negative cable. 18. Program radio stations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8109 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking Technical Service Bulletin # 04-4-1 Date: 040308 Frame - Rear Frame Side Member Cracking Article No. 04-4-1 03/08/04 ^ CHASSIS - FRAME CRACKING - SERVICE PROCEDURE ^ SUSPENSION - FRAME CRACKING - SERVICE PROCEDURE FORD: 1998-2002 CROWN VICTORIA ISSUE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8115 Some 1998-2002 Crown Victoria vehicles used for heavy-duty type service (Police/Taxi/Limo) may exhibit cracks in the rear of the frame side member between the upper and lower trailing arm brackets, or around the opening to the lower trailing arm bracket access hole for the flag nut in the bottom of the frame. These cracks may result from driving events that place extreme stress on the frame (i.e. rear vehicle impact, driving over curbs, high speed through driveway transitions, becoming airborne etc...). Refer to Figures 1, 2 and 3 for examples of cracks. ACTION To service, perform the following procedures to repair the cracks and reinforce the frame. NOTE READ THESE REPAIR INSTRUCTIONS IN THEIR ENTIRETY BEFORE BEGINNING ANY REPAIR. NOTE INSPECT THE VEHICLE FOR COLLISION OR ABUSE-RELATED DAMAGE THAT WOULD HINDER THIS SERVICE PROCEDURE. NOTE ONE KIT WILL REPAIR ONE SIDE OF THE FRAME. IF THE CONDITION IS OBSERVED ON BOTH SIDES OF THE VEHICLE'S FRAME, THEN TWO (2) KITS WILL BE REQUIRED. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8116 NOTE EACH KIT IS EQUIPPED WITH TW6 (2) REINFORCEMENT PLATES, ONE (1) FOR THE LEFT AND ONE (1) FOR THE 'RIGHT HAND SIDE OF THE FRAME. AT THE END OF THE REPAIR, ONE (1) OF THE REINFORCEMENTS FROM EACH KIT WILL BE LEFT OVER. (EXAMPLE: IF A KIT IS USED TO FIX THE RIGHT HAND SIDE OF THE FRAME, THERE WILL BE A LEFT HAND REINFORCEMENT BRACKET LEFT OVER AFTER THE REPAIRS ARE COMPLETED, AND VICE VERSA). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 040401A Repair Cracks In One 4.2 Hrs. Frame Rail Then Install Reinforcement Plates And Structural Foam 040401B Repair Cracks In Both 4.5 Hrs. Frame Rails Then Install Reinforcement Plates And Structural Foam DEALER CODING CONDITION BASIC PART NO. CODE 5B118 01 Disclaimer Service Procedure NOTE PERFORM THE FOLLOWING PROCEDURES AS NECESSARY TO REPAIR CRACKS AND REINFORCE ONE OR BOTH SIDES OF THE FRAME. IT SHOULD BE NOTED THAT IF THE VEHICLE IS SUBJECTED TO A HIGH STRESS EVENT AGAIN, NEW CRACKS MIGHT APPEAR IN THAT AREA. CAUTION ALWAYS DISCONNECT THE BATTERY GROUND CABLE PER WORKSHOP MANUAL SECTION 414-01 BEFORE USING ANY ELECTRICAL WELDING EQUIPMENT. USE ONLY MIG ER-70-56 WIRE WHEN WELDING. REAR FRAME AND BODY SPLIT NOTE DO NOT PERFORM THIS PROCEDURE IF THERE IS NO CRACK ON THE TOP SURFACE OF THE FRAME. In this procedure the bumper cover will be loosened to prevent damage to the cover when the body of the vehicle is lifted away from the vehicle frame. The frame will be split from the body to provide clearance necessary to repair cracks on the top of the vehicle frame. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8117 1. Position the vehicle on a hoist making sure there is adequate access to the body mount bolts (Figure 4) and the lower trailing arm flag nut access hole (see Workshop Manual Section 100-02). 2. Open the hood and disconnect the battery per Workshop Manual Section 414-01. 3. Open the trunk. 4. Remove/place aside the trunk trim on the sides and remove the four (4) rear bumper cover nuts in the trunk (two (2) on each side) (Figure 5 shows left hand side). NOTE IT IS NOT NECESSARY TO REMOVE THE LUGGAGE COMPARTMENT REAR TRIM PANEL. 5. Raise the vehicle to chest height. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8118 6. Remove the rear wheels. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8119 7. Remove the rear bumper cover screws from under the bumper fascia rear lip (two (2) or three (3) screws), (Figure 6) and the push pin type retainers from bottom sides of bumper cover (two (2) or three (3) on each side) (Figure 7), six (6) push pin-type retainers (three (3) on each side) in the wheel well at the leading edge of the bumper (Figure 8). 8. Remove the # 2, 3, 4, 5, and 6 body mount bolts on both sides. Refer to (Figure 4) for locations of body mount bolts. NOTE THE # 4 BODY MOUNT BOLTS ARE NEAR THE SPRING SEAT. 9. Install a 2X6 block of wood and two (2) jackscrews up tight against the body between the body drain plugs, partially under the trunk and the fuel tank (Figure 9). 10. It present, unclip the ground strap from the # 6 body holes on the frame on the right and left hand sides. The ground straps are located between the # 6 body hole and the rear cross member. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8120 NOTE DURING STEP 11, WATCH THE BUMPER COVER TO MAKE SURE IT DOES NOT HANG UP ON THE BUMPER REINFORCEMENT BAR. IF IT HANGS UP, THE BUMPER COVER MAY BE DAMAGED. 11. With the jackscrews and wood supporting the weight of the rear of the body, SLOWLY lower the lift so that the body splits from the frame. It will be necessary to create about a 12.7 cm (5") air gap between the frame and the body, at the # 5 body mounts location. Insert a 11.5 to 12.7 mm (4.5" to 5") tall block of 4X4 wood between the frame and the body mounts at the # 5 body mount location on both sides of the vehicle. The block will be flush to the cage nut reinforcement (Figure 10). 12. Raise the hoist and remove the jackscrews. REPAIR OF FRAME CRACKS BETWEEN THE UPPER AND LOWER TRAILING ARM MOUNTING BRACKETS NOTE REFER TO (FIGURES 1 AND 2) FOR THE TYPICAL LOCATION OF THE CRACKS. DO NOT PERFORM THIS PROCEDURE IF CRACKS ARE NOT PRESENT ON THE SIDE RAIL BETWEEN THE UPPER AND LOWER TRAILING ARM BRACKETS. NOTE PERFORM THIS REPAIR ON BOTH SIDES OF THE FRAME IF NECESSARY. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8121 1. If necessary, bend the spot-welded flange at the bottom edge of the inner fender well for improved access~to the frame crack (Figure 11). 2. On the left side only, remove the brake line clip and reposition the line away from welding area. 3. Use an angle grinder to clean off paint and dress the weld area. 4. Weld crack as necessary. 5. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to all weld repair areas. 6. Replace the brake line. 7. Re-bend weld flange into place. LOWER TRAILING ARM MOUNTING NUT ACCESS HOLE OPENING REPAIR AND/OR REINFORCEMENT In this procedure any cracks in the frame area around the lower trailing arm flag nut access hole opening will be repaired. A metal blocker baffle (4W73-4A145-AA) will be inserted into the side rail, and a reinforcement plate (4W73-5A123-AA or 4W73-5A124-M) will be welded to the bottom rail of the frame to close the access hole to strengthen that section hole. NOTE THE BLOCKER BAFFLE WILL PREVENT LEAKAGE OF THE STRUCTURAL FOAM, WHICH WILL BE INTRODUCED INTO THE FRAME. 1. Partially raise the vehicle and locate the access hole for the lower trailing arm. This access hole is located on the bottom of the frame, directly under the lower trailing arm mounting bracket. Inspect for cracks at the lower trailing arm access hole (Figure 3). If cracks are present repair them as necessary. 2. Use an angle grinder to clean off paint and dress the weld area. 3. Weld crack as necessary. 4. Bend two (2) metal Blocker Baffles (one (1) for each side) (4W73-5A145-M) along the crease on the middle of the part. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8122 5. Insert the baffle into the access hole with the narrow end facing upwards. Minimize bending the flanges. The blocker baffle will prevent the structural foam from running out of the frame and/or covering the trailing arm nut. The flanges should face the front of the car (Figure 12). 6. Once inside the rail section, unbend and position the blocker baffle to get a tight seal to the frame rail section. Perform one of the following procedures: a. On the left hand side bracket, line up the bottom edge of the blocker baffle flange to the rear edge of the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the top rear weld on the lower trailing arm bracket. Inspect the blocker baffle for a good seal between the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of the blocker baffle to improve seal between the blocker baffle and the frame. The flag nut may need to be bent out of the way to accommodate the blocker baffle. Tack weld the blocker baffle. b. On the right hand side bracket, line up the vertical face of the blocker baffle to the rear edge of the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the top rear weld on the lower trailing arm bracket (Figure 12). Inspect the blocker baffle for a good seal between the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of the blocker baffle to improve seal between the blocker baffle and the frame. Tack weld the blocker baffle. 7. Grind the area around the access hole in the bottom of the frame at the trailing arm, including any welds that may have been added to repair Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8123 cracks. Grind any welds where needed for proper location of the reinforcement patch (Figure 13). Do not grind away the parent metal. The reinforcement plate must be located flush to the frame. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8124 8. Center the slot of Reinforcement Patch (4W73-5A123-AA right hand side marked "R") or 4W73-5A124-M left hand side (marked "L") to the center of the trailing arm bolt taking care that the frame rail does not overlap the slot (Figure 14). Tack in place, then weld around the reinforcement plate completely (Figure 15 and 16). REINFORCE FRAME WITH STRUCTURAL FOAM In this procedure the frame rail section will be reinforced with Motorcraft Structural Foam that will add strength to the frame and reduce the potential for cracks in the frame in the area. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8125 1. Clean around the tooling hole and all other holes in the area on the frame rail located between the upper and lower trailing arm-mounting brackets (Figure 17 and 18). 2. Apply duct tape over the holes. 3. Pierce a 6 mm (1/4") hole into the duct tape covering the outer tooling hole to allow easy introduction of the nozzle into the tooling hole through the tape (Figure 19). 4. Lower the vehicle to chest height. NOTE IT IS SUGGESTED THAT GLOVES BE WORN WHEN WORKING THE HEATED TUBES OF MOTORCRAFT STRUCTURAL FOAM AS OUTLINED IN STEPS 5 THROUGH 7. ADDITIONALLY, THE STRUCTURAL FOAM WILL CAUSE THE SIDE MEMBER SURFACE TO BECOME VERY WARM AS A RESULT OF THE CHEMICAL REACTION. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8126 5. Put the five (5) tubes of 1U2J-19554-DA Motorcraft Structural Foam on a table and heat the tubes front and back with a heat gun to approximately 71.1 °C (160 °F). This will help soften the two parts of the Structural Foam so that it will flow out of the tubes and through the mixing wand easily (Figure 20). 6. Remove the small black plugs from a tube of structural foam. Install the nozzle (4W73-19H255-M) and replace the holding nuts. Balance the plungers by gunning out some material. Ensure that it comes out from both tubes. Press the tab on the back of the gun to relieve pressure. This will prevent the foam from streaming out of the tube uncontrollably. 7. Insert the nozzle through the hole cut into the duct tape in the outside tooling hole (Figure 19). Pump the tube of Structural Foam into the frame rail. When the Structural Foam rises to the height of the tooling hole, it will be necessary to duct tape the hole when switching tubes to prevent leakage of the Structural Foam. NOTE REPEAT STEPS 6-7 UNTIL ALL FIVE (5) TUBES OF 1U2J-19554-DA MOTORCRAFT STRUCTURAL FOAM HAVE BEEN PUMPED INTO THE FRAME. ALLOW AT LEAST THIRTY (30) MINUTES FOR THE STRUCTURAL FOAM TO CURE BEFORE REMOVING THE DUCT TAPE. 8. Raise the vehicle all the way up. 9. Remove duct tape. 10. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to the weld areas. REASSEMBLE FRAME AND BODY In the following steps the frame will be reassembled to the body, and the bumper fascia will be reinstalled. NOTE REQUIRED ONLY IF THE "REAR FRAME AND BODY SPLIT" PROCEDURE WAS PERFORMED. 1. Partially raise the vehicle. 2. Reinstall a 2X6 block of wood and two (2) jackscrews up tight against the body between the body drain plugs, partially under the trunk and the fuel tank (Figure 9). 3. Lower the hoist until the 2X6 block fits snug against the body. 4. Remove the wood block between the frame and the body mounts at the # 5 body mount location on each side of the vehicle (Figure 10). It may be necessary to further lower the hoist by 6 to 12 mm (1/4" to 1/2"). 5. SLOWLY raise the hoist until the frame is off the jackscrews and is flush with the body. Watch the bumper cover to make sure that it does not Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8127 become damaged. 6. Remove the jackscrews and the 2X6 block from under the vehicle. 7. Clip the ground strap to the #6 body holes on the frame on the right and left hand. 8. Reinstall the # 2, 3, 4, 5, and 6 body mount bolts on both sides. 9. Torque bolts to 48-50 N.m (35.4-36.8 lb-ft). 10. Partially lower the vehicle to waist height. 11. Relocate the bumper fascia and four (4) bumper cover nuts (two (2) on each side). 12. Torque bolts to 7 N.m (61.9 lb-in) (Figure 3 shows left hand side). 13. Reposition trunk trim sides. 14. Partially raise the vehicle. 15. Replace the six (6) pin-type retainers (three (3) on each side) in the wheel well leading edge of the bumper (Figure 8) and the push pin-type retainers (two (2) or three (3) on each side) from bottom sides of bumper cover (Figure 7). 16. Partially lower the vehicle. 17. Replace the rear wheel and tire assemblies. 18. Lower the hoist. 19. Close the trunk. 20. Reconnect the battery per Workshop Manual: Section 414-01. 21. Close the hood. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking Technical Service Bulletin # 99B09 Date: 990401 Campaign - Rear Frame Cosmetic Cracking 99B09 OWNER NOTIFICATION PROGRAM Certain 1998-1999 Ford Crown Victoria Police Interceptor, Taxi Cab, & Natural Gas Vehicles (NGV) & Lincoln Town Car Limousine Prep Package & Livery Vehicles Registered in the State of NY Commercial Vehicle Frame Service ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8133 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8134 Attachment I - Administrative Information OASIS OASIS will be activated for this program; however, only vehicles built on or before March 25, 1999 will be active in OASIS until a production action is incorporated. A supplement will be sent (estimated July, 1999) to all dealers when the remaining vehicles have been added to OASIS. If a vehicle, registered in New York but not listed in OASIS, is presented for service in that state and has the same package content and build dates as the "affected vehicles" described in this bulletin, dealers are to call 1-800-325-5621 and provide Ford Motor Company with a description of the concern, VIN, model year and mileage. If this information meets the requirements in this bulletin and the customer is willing to provide needed information, approval to perform repairs and submit a claim will be given by the Recall Hotline. PLEASE NOTE Correct all vehicles in stock before delivery. CLAIMS Enter claims using DWE. See ACESII Manual. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of rear frame cracks at the upper control arm access hole made before date of the Owner Letter enter using DWE: Attachment II - Labor and Parts Information Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8135 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 99B09 ^ Labor Operation: See above See ACESII manual for detailed instructions. Attachment III - Technical Information AFFECTED VEHICLE: 1998 AND 1999 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR (LIMO, LIVERY) SERVICE PROCEDURE 1. Record radio stations. 2. Disconnect battery negative cable. 3. Raise vehicle on hoist and remove rear wheels. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8136 4. Check to verify torque on both rear suspension upper arm pivot frame bolts is at minimum of 128 Nm (95 lb-ft). Refer to appropriate Service Repair Manual for proper bolt tightening procedure. Refer to Figure 1. 5. Cut off portion of RH flag nut's "flag" that protrudes from frame. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8137 6. Unclip ABS sensor wire from frame and position aside. Refer to Figure 2. 7. If equipped with air spring, wrap air spring in welding blanket. 8. CAUTION: If a crack is found, grind only enough metal away to form the V groove. Do not grind completely through frame parent metal. If frame is cracked, grind a V groove in crack, then remove E coat from around crack. Mig weld the groove using standard mig welding procedures. See Figure 2 for location of mig welder grounding clamp. 9. CAUTION: Only remove paint and any weld material that interferes with reinforcement plate fit. Do not grind frame parent metal. Prep the frame by removing any paint in the affected area. Grind only the welds that will interfere with the reinforcement plate sitting flush to the frame (plate must not "rock"). After grinding, position the plate to check that it sits flush and if necessary, strike any weld with a punch and hammer to deflect the metal enough to allow proper fit. 10. NOTE: Reinforcement plate is properly positioned when the entire access hole is covered and the rear edge is no more than 10 mm (approximately 3/8 in.) from the "lance" on the frame. If necessary, verify proper positioning by close inspection using a shop light. Refer to Figure 2. Position and clamp reinforcement plate onto frame completely covering access hole. 11. CAUTION: Burn-through is not permitted. If any burn-through occurs, the hole must be filled. Using standard mig welding procedures, tack weld reinforcement plate to frame on the two (2) outboard corners, then proceed to weld the perimeter of the reinforcement plate in sequence shown in Figure 2. 12. Remove weld blankets, if previously installed. 13. Spray undercoating on plate and welds being careful to avoid any overspray. 14. Reclip ABS sensor wire. 15. Repeat steps 6 through 14 for other side. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8138 16. Install tires. Tighten lug nuts to 129 Nm (95 lb-ft). Lower hoist. 17. Connect battery negative cable. 18. Program radio stations. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8139 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedures 1. Disconnect the battery ground cable and wait at least one minute. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedures 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Install the passenger air bag module. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8147 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the vehicle battery connected? Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair Glove Compartment Lock Cylinder: Service and Repair REMOVAL 1. Open glove compartment and remove lock cover. Remove four screws retaining lock cylinder. 2. Remove lock cylinder from glove compartment. INSTALLATION 1. To install, reverse Removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging Headliner: Customer Interest Dome Lamp/Headliner - Sagging Article No. 99-20-8 10/04/99 INTERIOR - HEADLINER SAGS - VEHICLES BUILT 12/1998 THROUGH 9/1999 FORD: 1999-2000 CROWN VICTORIA MERCURY: 1999-2000 GRAND MARQUIS ISSUE The interior dome lamp may not be adhered to the roof on some vehicles. This may be caused by the headliner material which was revised in the 1999 model to a less rigid material. During assembly in hot/humid conditions, the dome lamp may sag and lose contact with the roof sheet metal prior to the adhesive curing. ACTION Remove the interior dome lamp mounting bracket. Clean any residual adhesive from roof sheet metal. Install new mounting bracket with two-sided foam tape. This should provide an adhesive attachment between the headliner and roof sheet metal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the dome lamp lens. 2. Remove screws that secure the lamp assembly to the mounting bracket. 3. Disconnect the electrical connector to the lamp assembly. 4. Remove the black mounting bracket through the hole in the headliner. 5. Clean any adhesive from the roof sheet metal above the opening in the headliner. Use a putty knife to scrape off the adhesive. 6. Remove the plastic film from the foam tape on the back of the new mounting bracket. The adhesive should now be exposed. 7. Locate and align the new mounting bracket to the headliner opening. NOTE THE TWO (2) LONG LOCATOR PINS ARE AT THE REAR SIDE OF THE OPENING. 8. Push the mounting bracket and headliner up against the roof. NOTE: SIMULTANEOUSLY PUSH THE MOUNTING BRACKET AND HEADLINER UP TO ENSURE THE BRACKET STAYS CORRECTLY LOCATED. 9. Connect electrical connector to the lamp assembly. 10. Locate the lamp assembly to the mounting bracket. Tighten screws. 11. Install dome lamp lens. PART NUMBER PART NAME F3MZ-5451 536-BA Bracket - Single Light F5AZ-5451 536-BA Bracket - Dual Beam Light OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging > Page 8160 OPERATION DESCRIPTION TIME 992008A Install New Headliner 0.3 Hr. Bracket DEALER CODING CONDITION BASIC PART NO. CODE 5451536 33 OASIS CODES: 105000, 107000, 201100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging Headliner: All Technical Service Bulletins Dome Lamp/Headliner - Sagging Article No. 99-20-8 10/04/99 INTERIOR - HEADLINER SAGS - VEHICLES BUILT 12/1998 THROUGH 9/1999 FORD: 1999-2000 CROWN VICTORIA MERCURY: 1999-2000 GRAND MARQUIS ISSUE The interior dome lamp may not be adhered to the roof on some vehicles. This may be caused by the headliner material which was revised in the 1999 model to a less rigid material. During assembly in hot/humid conditions, the dome lamp may sag and lose contact with the roof sheet metal prior to the adhesive curing. ACTION Remove the interior dome lamp mounting bracket. Clean any residual adhesive from roof sheet metal. Install new mounting bracket with two-sided foam tape. This should provide an adhesive attachment between the headliner and roof sheet metal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the dome lamp lens. 2. Remove screws that secure the lamp assembly to the mounting bracket. 3. Disconnect the electrical connector to the lamp assembly. 4. Remove the black mounting bracket through the hole in the headliner. 5. Clean any adhesive from the roof sheet metal above the opening in the headliner. Use a putty knife to scrape off the adhesive. 6. Remove the plastic film from the foam tape on the back of the new mounting bracket. The adhesive should now be exposed. 7. Locate and align the new mounting bracket to the headliner opening. NOTE THE TWO (2) LONG LOCATOR PINS ARE AT THE REAR SIDE OF THE OPENING. 8. Push the mounting bracket and headliner up against the roof. NOTE: SIMULTANEOUSLY PUSH THE MOUNTING BRACKET AND HEADLINER UP TO ENSURE THE BRACKET STAYS CORRECTLY LOCATED. 9. Connect electrical connector to the lamp assembly. 10. Locate the lamp assembly to the mounting bracket. Tighten screws. 11. Install dome lamp lens. PART NUMBER PART NAME F3MZ-5451 536-BA Bracket - Single Light F5AZ-5451 536-BA Bracket - Dual Beam Light OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging > Page 8166 OPERATION DESCRIPTION TIME 992008A Install New Headliner 0.3 Hr. Bracket DEALER CODING CONDITION BASIC PART NO. CODE 5451536 33 OASIS CODES: 105000, 107000, 201100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 8167 Headliner: Service and Repair REMOVAL 1. Remove the front seats. 2. Remove the front door weatherstrips. 3. Remove the windshield side garnish mouldings. 4. Disconnect the connector from the RH windshield pillar. 5. Remove the interior sun visors. 6. Remove the upper trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 8168 7. Remove the passenger assist handles. 8. Remove the upper trim panels. 9. Remove the pin-type retainers. 10. Using a hot knife or wide-blade putty knife, cut adhesive beads lengthwise across the headliner. NOTE: Pull down sides of headliner above the door openings to expose adhesive beads. 11. Remove the headliner through the front door opening. NOTE: A new headliner must be installed if the headliner is folded in half for removal. 12. Clean any remaining adhesive from the roof sheet metal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: A new headliner will need to be installed if it is folded during removal or installation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair Rear Shelf: Service and Repair REMOVAL 1. Remove the rear seat cushion. 2. Remove the nut from each side. 3. Remove the seat backrest. 4. Remove the roof side rear trim panels. 5. Remove the screw from each side. 6. Remove the high mounted stoplamp. 7. Remove the high mounted stoplamp brackets. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Page 8172 8. Remove the pin-type retainers. 9. Remove the package tray trim panel. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel Trim Panel: Service and Repair B-Pillar Trim Panel REMOVAL 1. Remove the front door scuff plate. 2. Remove the rear door scuff plate. 3. Pull back the front and rear door weatherstrips to clear the trim panels. 4. Remove the center body pillar lower finish panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 8177 5. Remove the center D-ring cover. 6. Remove the nut. 7. Remove the upper trim pillar. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 8178 Trim Panel: Service and Repair Quarter Trim Panel REMOVAL 1. Remove the rear seat cushion. 2. Remove the nut from each side. 3. Remove the seat backrest. 4. Partially remove the weatherstrip to clear the roof side rear trim panel. 5. Remove the rear seat shoulder strap opening bezel. 6. Remove the pin-type retainer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 8179 7. Remove the bolt. 8. Remove the roof side rear trim panel. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Door Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8186 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8187 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8188 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8189 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8190 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Page 8191 Door Lock Cylinder: Description and Operation Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Front Door Door Lock Cylinder: Service and Repair Front Door REMOVAL 1. Remove the exterior door handle. NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using a appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 2. Disconnect door lock cylinder rod. 3. Remove the clip. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using a appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Front Door > Page 8194 Door Lock Cylinder: Service and Repair Luggage Compartment Door REMOVAL 1. Remove the nuts from each side NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using a appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 2. Disconnect the cable. 3. Disconnect the connectors. 4. Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Front Door > Page 8195 5. Remove the reflector lens assembly. 6. Remove the license lamp bulb. 7. Remove the rivets. 8. Remove the lock cylinder INSTALLATION 1. To install, reverse the removal procedure. NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using a appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 8200 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door panel. 3. Position weathershield aside. 4. Remove the keyless entry keypad. 1 Remove the Clip. ^ Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair 1. Cycle the ignition from OFF to RUN four times within three seconds. The locks will then lock and unlock, confirming program mode has been entered. 2. Press any button on the transmitter to be programmed. NOTE: When the first keyless entry remote transmitter is programmed, all other keyless entry remote transmitters are erased. 3. If additional keyless entry remote transmitters are to be programmed, repeat step 2 within 7.5 seconds. 4. To exit program mode, turn the ignition to START or wait 7.5 seconds. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair Power Door Lock Actuator: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the latch. 3. Pivot the actuator. 4. Remove the actuator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8212 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8213 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8214 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8215 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8216 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8217 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8218 Power Door Lock Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8219 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8220 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8221 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8222 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8223 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8224 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8225 Power Door Lock Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8226 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8227 Power Door Lock Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8228 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8229 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Page 8230 Power Door Lock Control Module: Service and Repair REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door trim panel. 3. Remove the Driver Door Module (DDM). 1 Disconnect the electrical connector. 2 Remove the screws. 3. Release the locking tab. INSTALLATION CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 8235 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch Power Door Lock Switch: Testing and Inspection LF Door Lock Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 8238 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 8239 Power Door Lock Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 8240 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Page 8241 Power Door Lock Switch: Service and Repair REMOVAL 1. Remove the window regulator switch plate. 2. Remove the screws. 3. Disconnect the connector. 4. Remove the door lock switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8246 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8247 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8248 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8249 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8250 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Mirror Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8256 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8257 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8258 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8259 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8260 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8261 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8262 Power Mirror Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8263 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8264 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8265 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8266 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8267 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8268 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8269 Power Mirror Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8270 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8271 Power Mirror Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8272 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8273 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair REMOVAL 1. Remove the exterior rear view mirror. 2. Push in the upper edge of the exterior rear view mirror glass to the maximum travel and gently pull outward until the exterior rear view mirror glass is released. 3. Remove the screws. 4. Remove the motor. NOTE: Note the colors and locations of the connectors prior to removal. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 8280 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 8281 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 8282 Power Mirror Switch: Service and Repair REMOVAL 1. Remove the window regulator switch plate from the front door trim panel. CAUTION: Use a shop towel or similar material between the tool and the front door trim panel or damage to the front door trim panel may occur. 2. Release the tabs. 3. Remove the exterior rear view mirror control switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8292 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8293 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8294 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8295 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8296 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8302 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8303 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8304 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8305 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8306 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8307 Paint: By Symptom Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8308 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8309 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8310 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8311 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8312 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8313 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8314 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8315 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8316 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 8317 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8323 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8324 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8325 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8326 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8327 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8328 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8329 Power Door Lock Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8330 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8331 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8332 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8333 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8334 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8335 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8336 Power Door Lock Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8337 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8338 Power Door Lock Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8339 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8340 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 8341 Power Door Lock Control Module: Service and Repair REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door trim panel. 3. Remove the Driver Door Module (DDM). 1 Disconnect the electrical connector. 2 Remove the screws. 3. Release the locking tab. INSTALLATION CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Mirror Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8346 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8347 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8348 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8349 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8350 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8351 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8352 Power Mirror Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8353 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8354 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8355 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8356 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8357 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8358 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8359 Power Mirror Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8360 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8361 Power Mirror Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8362 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8363 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Seat Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8368 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8369 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8370 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8371 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8372 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8373 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8374 Power Seat Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8375 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8376 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8377 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8378 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8379 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8380 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8381 Power Seat Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 Power Seat Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8385 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Seat Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8396 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8397 Power Seat Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8400 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8401 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8402 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8403 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8404 Power Seat Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8405 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8406 Power Seat Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8407 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8408 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver's Seat Motor Assembly Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver's Seat Motor Assembly > Page 8413 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 8414 Power Seat Motor: Service and Repair REMOVAL 1. Remove the seat. 2. Remove the seat track. 3. Disconnect the connector. 4. Disconnect the hose. 5. Remove the lumbar motor. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch Power Seat Switch: Diagrams Driver's Seat Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch > Page 8419 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch Power Seat Switch: Testing and Inspection Driver's Seat Control Switch Driver Seat Control Switch (All Others) Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8422 Schematic Driver Seat Control Switch (Base and Police) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8423 Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8424 Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8425 Power Seat Switch: Testing and Inspection Passenger Seat Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8426 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8427 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch Power Seat Switch: Service and Repair Front Seat Occupied Switch REMOVAL 1. Disconnect the battery. 2. Remove the seat. 3. Remove the seat track. 4. Disconnect the connector. 5. Slide the retainers outboard. 6. Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch > Page 8430 Power Seat Switch: Service and Repair Lumbar Seat Control Switch REMOVAL 1. Disconnect the battery. 2. Remove the seat. 3. Remove the cover. 4. Remove the screws. 5. Disconnect the connector. 6. Disconnect the vacuum tubes. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch > Page 8431 NOTE: Mark the tubes before disconnecting. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch > Page 8432 Power Seat Switch: Service and Repair Seat Regulator Control Switch REMOVAL 1. Disconnect the battery. 2. Remove the front door trim panel. 3. Remove the seat regulator control switch. 1 Remove the screws. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair Seat Cushion: Service and Repair DISASSEMBLY 1. Remove the seat. 2. Remove the seat track. 3. Remove the lumbar motor. 4. Release the retainers. 1 Release the J retainers. 2 Remove the pin-type retainer. 5. Remove the cover. 6. Remove the retaining clip. 7. Remove the pin. 8. Remove the armrest. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Page 8436 9. Remove the armrest cover trim. 10. Remove the frame. 11. Remove the bolts. 12. Remove the seat occupy switch. 13. Remove the seat trim cover. ASSEMBLY 1. To install, reverse the disassembly procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Description and Operation Seat Latch: Description and Operation WARNING: THE INERTIA FRONT SEAT BACKREST LATCH ASSEMBLY IS FACTORY-INSTALLED IN ITS CORRECT LOCATION. CUSTOMER OR DEALER MAINTENANCE IS NOT REQUIRED. CORRECT FRONT SEAT BACKREST LATCH FUNCTION IN EMERGENCY SITUATIONS REQUIRES THAT THE SEAT BACKREST BE IN ITS FULL REARWARD NORMAL POSITION AND AGAINST THE REARWARD STOPS IN THE FRONT SEAT BACKREST LATCH ASSEMBLY. THEREFORE, THE AREA BEHIND THE SEAT MUST BE KEPT CLEAR AT ALL TIMES TO ALLOW FULL REARWARD TRAVEL OF THE SEAT BACKREST. IN ADDITION, REAR SEAT PASSENGERS SHOULD NOT LEAN ON THE FRONT SEAT BACKREST WHILE THE VEHICLE IS IN MOTION. THE FORWARD FORCE ON THE SEAT BACKREST FROM THE REAR PASSENGER IN AN EMERGENCY SITUATION MAY PREVENT CORRECT OPERATION OF THE INERTIA FRONT SEAT BACKREST LATCH MECHANISM. NOTE: The front seat backrest latch must be installed as new if any component is non-functional or damaged. ^ The inertia front seat backrest latch remains unlocked with normal usage, and locks only during vehicle deceleration (emergency stopping or upon impact) or on steep downhill grades. ^ A manual (override) release handle is provided only to help unlock the front seat backrest latch in the event of front seat backrest latch lockup. The only authorized repair of the front seat backrest latch includes: ^ tightening of the retaining screws to the correct specification ^ installing a new front seat backrest latch ^ removal of any foreign material, such as tie straps, pieces of foam and trim Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only Seat Track: Service and Repair Driver Side Only REMOVAL CAUTION: Use care when handling the seat and track assembly. dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 1. Remoce the front seat. 2. Disconnect the connector. 3. Remove the nut. 4. Pull the buckle through the cushion opening. 5. Release the J retainer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8444 6. Release the J retainer. 7. Remove the bolts. 8. Remove the pivot bolt. 9. Disconnect the connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8445 10. Remove the bolts. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8446 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8447 Seat Track: Service and Repair Except Driver Side REMOVAL CAUTION: Use care when handling the seat and track assembly. dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 1. Remove the front seat. 2. Remove the nut. 3. Pull the buckle through the cushion opening. 4. Release the J retainer. 5. Release the J retainer. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8448 6. Remove the bolts. 7. Remove the pivot bolt. 8. Disconnect the connector. 9. Remove the bolts. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8449 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Fuel Door Lock Switch > Component Information > Description and Operation Fuel Door Lock Switch: Description and Operation The fuel filler door lock switch: - actuates a solenoid integral to the fuel filler door latch to release the fuel filler door. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 8463 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch Power Door Lock Switch: Testing and Inspection LF Door Lock Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 8466 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 8467 Power Door Lock Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 8468 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Page 8469 Power Door Lock Switch: Service and Repair REMOVAL 1. Remove the window regulator switch plate. 2. Remove the screws. 3. Disconnect the connector. 4. Remove the door lock switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 8473 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 8474 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 8475 Power Mirror Switch: Service and Repair REMOVAL 1. Remove the window regulator switch plate from the front door trim panel. CAUTION: Use a shop towel or similar material between the tool and the front door trim panel or damage to the front door trim panel may occur. 2. Release the tabs. 3. Remove the exterior rear view mirror control switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch Power Seat Switch: Diagrams Driver's Seat Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch > Page 8480 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch Power Seat Switch: Testing and Inspection Driver's Seat Control Switch Driver Seat Control Switch (All Others) Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8483 Schematic Driver Seat Control Switch (Base and Police) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8484 Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8485 Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8486 Power Seat Switch: Testing and Inspection Passenger Seat Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8487 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 8488 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch Power Seat Switch: Service and Repair Front Seat Occupied Switch REMOVAL 1. Disconnect the battery. 2. Remove the seat. 3. Remove the seat track. 4. Disconnect the connector. 5. Slide the retainers outboard. 6. Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch > Page 8491 Power Seat Switch: Service and Repair Lumbar Seat Control Switch REMOVAL 1. Disconnect the battery. 2. Remove the seat. 3. Remove the cover. 4. Remove the screws. 5. Disconnect the connector. 6. Disconnect the vacuum tubes. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch > Page 8492 NOTE: Mark the tubes before disconnecting. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Occupied Switch > Page 8493 Power Seat Switch: Service and Repair Seat Regulator Control Switch REMOVAL 1. Disconnect the battery. 2. Remove the front door trim panel. 3. Remove the seat regulator control switch. 1 Remove the screws. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8502 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8503 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8504 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification Weatherstrip: All Technical Service Bulletins Door Weatherstrip - Replacement Identification Article No 99-13-12 06/28/99 DOOR - IDENTIFYING CORRECT REPLACEMENT DOOR WEATHERSTRIP FORD: 1999 CROWN VICTORIA MERCURY: 1999 GRAND MARQUIS ISSUE This article is published to help identify correct replacement 1999 model door sealing weatherstrip. A mid-year change to improve the door sealing weatherstrips introduced new seals. Parts affected include the primary seal on the doors, weatherstrip seal on the door opening, and the roof side weatherstrip Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification > Page 8510 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification > Page 8511 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification > Page 8512 ACTION Correctly identify the weatherstrip on the vehicle and assist in determining replacement parts. Figures 1, 2 and 3 provide cross-sections of the original and new weatherstrips and should be used for comparison. The following Tables should be used to determine the correct service replacement part. NOTE MIXING ORIGINAL AND NEW PARTS CAN CAUSE WINDNOISE DEGRADATION OR HIGH DOOR CLOSING EFFORTS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8517 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8518 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8519 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification Weatherstrip: All Technical Service Bulletins Door Weatherstrip - Replacement Identification Article No 99-13-12 06/28/99 DOOR - IDENTIFYING CORRECT REPLACEMENT DOOR WEATHERSTRIP FORD: 1999 CROWN VICTORIA MERCURY: 1999 GRAND MARQUIS ISSUE This article is published to help identify correct replacement 1999 model door sealing weatherstrip. A mid-year change to improve the door sealing weatherstrips introduced new seals. Parts affected include the primary seal on the doors, weatherstrip seal on the door opening, and the roof side weatherstrip Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification > Page 8525 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification > Page 8526 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification > Page 8527 ACTION Correctly identify the weatherstrip on the vehicle and assist in determining replacement parts. Figures 1, 2 and 3 provide cross-sections of the original and new weatherstrips and should be used for comparison. The following Tables should be used to determine the correct service replacement part. NOTE MIXING ORIGINAL AND NEW PARTS CAN CAUSE WINDNOISE DEGRADATION OR HIGH DOOR CLOSING EFFORTS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Diagrams > Page 8532 Deactivator Switch: Adjustments NOTE: For proper adjustment, the deactivator switch must be removed and reinstalled. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch Deactivator Switch: Service and Repair Brake Pedal Position (BPP) Switch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower insulator. 1 Remove the push pins. 2 Disconnect the interior lamp. 3 Remove the lower insulator. 3. Disconnect the Brake Pedal Position (BPP) switch. 4. Remove the BPP switch. 1 Remove the cotter pin. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 8535 2 Remove the sleeve. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 8536 Deactivator Switch: Service and Repair Deactivator Switch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the deactivator switch. 1 Disconnect the electrical connector. 2 Rotate counterclockwise and remove the deactivator switch. INSTALLATION 1. Pull the plunger out to its full travel. 2. Fully depress the brake pedal. 3. Install the deactivator switch. 1 Position the deactivator switch in the bracket and rotate clockwise. 2 Connect the electrical connector. 4. Slowly release the brake pedal. 5. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Bracket to Speed Control Servo Screw ............................................................................................................................................. 8-11 N.m (71-97 Lb-In) Speed Control Servo Nut ............................................................................................... ..................................................................... 5-7 N.m (45-62 Lb-In) Engine Cover Nut ....................... ....................................................................................................................................................... 6-10 N.m (62-89 Lb-In) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 8540 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 8541 Cruise Control Servo: Service and Repair REMOVAL 1. Remove the speed control actuator cable. 2. Disconnect the speed control servo electrical connector. 3. Remove the speed control servo and bracket. 1 Remove the bolts. 2 Remove the speed control servo and bracket. 4. Remove the speed control servo bracket. 1 Remove the screws. 2 Remove the speed control servo bracket. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 8542 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications Cruise Control Servo Cable: Specifications Battery Ground Cable .......................................................................................................................... ............................................. 7-10 N.m (62-89 Lb-In) Engine Cover Nut ............................................. ................................................................................................................................. 6-10 N.m (62-89 Lb-In) Speed Control Actuator Cable-to- Accelerator Cable Bracket Bolt .......................................................................................................................................................... 3-4 N.m (27-35 Lb-In) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 8546 Cruise Control Servo Cable: Adjustments 1. Remove the retaining clip from the speed control actuator cable adjuster. 2. Pull on the speed control actuator cable to take up slack, then back off at least one notch so there is approximately 3 mm (0.118 in) of slack in the speed control actuator cable. NOTE: Ensure the throttle is in the fully closed position. 3. Insert the speed control actuator cable retaining clip and snap into place. 4. Verify that the throttle linkage operates freely and smoothly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 8547 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Remove the engine cover. 1 Remove the nut. 2 Remove the engine cover. 2. Remove the speed control actuator cable from the throttle lever. 1 Remove the bolt. 2 Remove the speed control actuator cable from the throttle lever. 3. Remove the speed control actuator cable cap. 1 Depress the locking tab. 2 Remove the speed control actuator cable cap. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 8548 4. Remove the speed control actuator cable from the speed control servo pulley. 1 Remove the speed control cable slug. 2 Remove the speed control actuator cable. INSTALLATION 1. Insert the speed control cable slug into the speed control servo pulley slot. 2. Release the compressed spring while aligning the speed control actuator cable cap tabs with the slots in the speed control servo housing. NOTE: Ensure the rubber seal is fully seated onto the speed control actuator cable cap. - Incorrect wrapping of the speed control actuator cable around the speed control servo pulley may result in a high idle condition. 3. Rotate the speed control actuator cable cap until the locking tab engages. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 8549 4. Connect the speed control actuator cable to the throttle lever. 1 Install the bolt. 2 Connect the speed control actuator cable to the throttle lever by snapping into place. 5. Adjust the speed control actuator cable. 6. Install the engine cover. 1 Position the engine cover. 2 Install the nut. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the steering wheel cover screws. 3. Remove the steering wheel cover. 1 Position the steering wheel cover aside. 2 Disconnect the electrical connector and wire harness from the steering wheel cover. 3 Remove the steering wheel cover. 4. Remove the speed control actuator switches. 1 Push the speed control actuator switches out towards the face of the steering wheel. 2 Position the speed control actuator switches through the steering wheel openings and remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Diagrams > Page 8557 Deactivator Switch: Adjustments NOTE: For proper adjustment, the deactivator switch must be removed and reinstalled. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch Deactivator Switch: Service and Repair Brake Pedal Position (BPP) Switch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower insulator. 1 Remove the push pins. 2 Disconnect the interior lamp. 3 Remove the lower insulator. 3. Disconnect the Brake Pedal Position (BPP) switch. 4. Remove the BPP switch. 1 Remove the cotter pin. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 8560 2 Remove the sleeve. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 8561 Deactivator Switch: Service and Repair Deactivator Switch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the deactivator switch. 1 Disconnect the electrical connector. 2 Rotate counterclockwise and remove the deactivator switch. INSTALLATION 1. Pull the plunger out to its full travel. 2. Fully depress the brake pedal. 3. Install the deactivator switch. 1 Position the deactivator switch in the bracket and rotate clockwise. 2 Connect the electrical connector. 4. Slowly release the brake pedal. 5. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the steering wheel cover screws. 3. Remove the steering wheel cover. 1 Position the steering wheel cover aside. 2 Disconnect the electrical connector and wire harness from the steering wheel cover. 3 Remove the steering wheel cover. 4. Remove the speed control actuator switches. 1 Push the speed control actuator switches out towards the face of the steering wheel. 2 Position the speed control actuator switches through the steering wheel openings and remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The anti-lock brake warning indicator illuminates when the anti-lock brake control module detects a fault in the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Page 8569 ABS Light: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Cluster, Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 8578 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 8584 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8587 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8588 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8589 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8590 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8591 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8592 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8593 Audible Warning Device: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8594 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8595 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8596 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8597 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8598 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8599 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8600 Audible Warning Device: Electrical Diagrams Diagram 66-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8601 Diagram 66-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Principles of Operation Audible Warning Device: Description and Operation Principles of Operation Chimes and tones are produced and managed by the Lighting Control Module (LCM). The LCM provides sound for three different functions: reminder chimes, depression tones for the fuel computer switches and the electronic crash sensor (ESC) warning chime. The reminder chime alerts the driver to conditions that require attention, such as an unfastened safety belt, the key in ignition when the driver door is open and headlamps or parklamps left on with the ignition switch in the OFF position. When the ignition switch is turned to RUN or START from OFF or ACC, the safety belt warning chime will sound for six seconds or until the safety belt is buckled. The safety belt warning indicator lamp will turn on for 60 seconds or until the driver seat belt is buckled. Both the chime and lamp will turn on at the same time. If the safety belt is buckled before the ignition switch is turned to RUN or START from OFF or ACC, neither the chime nor the lamp will be activated. The key-in-ignition warning chime will sound when the driver side door is opened with the key in the ignition and the ignition switch is in the OFF or ACC position. It will continue to sound until the key is removed, the front door is closed or the ignition switch is turned to RUN or START. The headlamp-on reminder chime will be activated if the headlamps are on, the key is not in the ignition and the driver door is opened. The ECS warning chime will sound when a faulty ECS module is detected. The ESC module requests a tone via a hard wired signal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Principles of Operation > Page 8604 Audible Warning Device: Description and Operation Warning Devices The warning device (chimes) system consists of the following components: ^ key-in-ignition warning switch ^ door ajar switch ^ Lighting Control Module (LCM) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Audible Warning Device: Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Door ajar switches Electrical ^ Central Junction Box (CJB) Fuses 4 (15 A), 8 (15 A), 6 (15 A), 13 (15 A), circuit breaker 12 (18 A) ^ Circuitry ^ Damaged or corroded connectors ^ Lighting Control Module (LCM) ^ Electronic instrument cluster ^ Electronic Crash Sensor (ECS) module 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Pinpoint Tests/A: No Communication With Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self- test diagnostics for the LCM module. 6. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8607 Audible Warning Device: Diagnostic Trouble Code Descriptions Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8608 Part 2 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8609 Part 3 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8610 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8611 Audible Warning Device: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8612 A1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8613 A2 - A3 B: No Communication W/Module - Unable to Enter Self-Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8614 B1 - B2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8615 B3 - B4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8616 B5 C: The Headlamp Reminder Chime Doesn't Operate Correctly C1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8617 C2 - C4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8618 C5 D1 - D2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8619 D3 - D4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8620 E1 - E2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8621 E3 - E4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8622 F1 - F3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8623 F4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8624 G1 - G4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8625 G5 - G6 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8626 Audible Warning Device: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Door ajar switches Electrical ^ Central Junction Box (CJB) Fuses 4 (15 A), 8 (15 A), 6 (15 A), 13 (15 A), circuit breaker 12 (18 A) ^ Circuitry ^ Damaged or corroded connectors ^ Lighting Control Module (LCM) ^ Electronic instrument cluster ^ Electronic Crash Sensor (ECS) module 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Pinpoint Tests/A: No Communication With Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self- test diagnostics for the LCM module. 6. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Diagnostic Trouble Code Descriptions Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8627 Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8628 Part 2 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8629 Part 3 Of 3 Icons Used With Pinpoint Tests Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8630 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8631 A1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8632 A2 - A3 B: No Communication W/Module - Unable to Enter Self-Test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8633 B1 - B2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8634 B3 - B4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8635 B5 C: The Headlamp Reminder Chime Doesn't Operate Correctly C1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8636 C2 - C4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8637 C5 D1 - D2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8638 D3 - D4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8639 E1 - E2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8640 E3 - E4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8641 F1 - F3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8642 F4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8643 G1 - G4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8644 G5 - G6 Principles of Operation Chimes and tones are produced and managed by the Lighting Control Module (LCM). The LCM provides sound for three different functions: reminder chimes, depression tones for the fuel computer switches and the electronic crash sensor (ESC) warning chime. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8645 The reminder chime alerts the driver to conditions that require attention, such as an unfastened safety belt, the key in ignition when the driver door is open and headlamps or parklamps left on with the ignition switch in the OFF position. When the ignition switch is turned to RUN or START from OFF or ACC, the safety belt warning chime will sound for six seconds or until the safety belt is buckled. The safety belt warning indicator lamp will turn on for 60 seconds or until the driver seat belt is buckled. Both the chime and lamp will turn on at the same time. If the safety belt is buckled before the ignition switch is turned to RUN or START from OFF or ACC, neither the chime nor the lamp will be activated. The key-in-ignition warning chime will sound when the driver side door is opened with the key in the ignition and the ignition switch is in the OFF or ACC position. It will continue to sound until the key is removed, the front door is closed or the ignition switch is turned to RUN or START. The headlamp-on reminder chime will be activated if the headlamps are on, the key is not in the ignition and the driver door is opened. The ECS warning chime will sound when a faulty ECS module is detected. The ESC module requests a tone via a hard wired signal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8646 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Page 8647 Audible Warning Device: Service and Repair REMOVAL 1. Remove the ignition lock cylinder. 1 Insert the key into the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Release the clip. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure ^ Verify ignition lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module Audible Warning Device Control Module: Diagrams Lighting Control Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module > Page 8652 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module > Page 8653 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation The brake system warning indicator has a dual function. It illuminates when the parking brake is applied or when a low brake fluid condition exists in the brake master cylinder reservoir. The brake system warning indicator will illuminate when there is a pressure differential between the front and rear brake hydraulic systems. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation Charge Lamp/Indicator: Description and Operation The charging system indicator illuminates whenever the generator output is insufficient to maintain battery state of charge or if the generator output is too high. Under normal operation, the indicator goes out after the engine is started and the charging system begins to operate. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8665 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8666 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8667 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8668 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 Cigarette Lighter: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8671 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8672 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8673 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8674 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8675 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8676 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8677 Diagram 44-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Specifications Clock: Specifications Instrument Cluster Finish Panel Bolts 2-3 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions Clock: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8683 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8684 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8685 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8686 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8687 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8688 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8689 Clock: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8690 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8691 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8692 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8693 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8694 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8695 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8696 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8697 Diagram 44-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 8698 Clock: Description and Operation The electric clock is centrally located on the instrument panel and displays time in a 12 hour format. The display illuminates with the ignition switch in ACC or RUN and dims when the headlamps are on. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Clock: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged electric clock Electrical ^ Blown fuse: Central Junction Box (CJB) Fuse 8 (15 A) - (CJB) Fuse 6 (15 A) ^ Damaged wire(s) ^ Loose or corroded connections 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8701 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8702 Clock: Pinpoint Tests Icons Used With Pinpoint Test Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8703 A1 - A2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8704 73 Digital Multimeter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 8705 Clock: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the RH instrument panel finish panel. ^ Disconnect the electrical connector. 3. Remove the electric clock. 1 Remove the screws. 2 Remove the electric clock. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation Compass: Description and Operation The compass: ^ is incorporated into the inside rear view mirror. ^ has a two-character display in the upper RH side of the mirror, which indicates the direction in which the vehicle is pointed (N, NE, E, SE, S, SW, W, NW). ^ uses an electronic compass sensor built into the inside rear view mirror. ^ has compass adjustment (calibration and zone variation) controlled by a COMP switch on the mirror. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 1. Verify the customer concern by operating the vehicle along roads of known direction to duplicate the customer concern with the compass. 2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical ^ Physical damage to mirror assembly Electrical ^ Blown fuse: Central Junction Box (CJB) Fuse 5 (15 A) ^ Damaged wiring harness ^ Loose or corroded connectors ^ Damaged compass sensor (part of inside rear view mirror) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8711 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8712 Compass: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8713 A1 - A2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8714 B1 - B2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8715 B3 - B4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8716 73 Digital Multimeter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Calibration Adjustment Compass: Adjustments Compass Calibration Adjustment 1. Press and hold the COMP button until C appears (six seconds). Release the COMP button. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (rear window defrost, heater, A/C, map lamps and wipers) and make sure all doors are shut. 2. Drive the vehicle at less than 8 km/h (5 mph) a continuous circle until the display turns off. 3. If the C message does not turn off within five circles, demagnetize the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Calibration Adjustment > Page 8719 Compass: Adjustments Compass Zone Adjustment 1. Refer to the compass calibration zone map to select the correct compass zone setting for your geographical location. 2. With the compass display turned on, press and hold the COMP button (for three seconds) until the display shows the current zone of operation. 3. Momentarily press the COMP button to cycle the zone number display. Set the zone display number to match the vehicle location on the compass calibration zone map. 4. Releasing the switch for 10 seconds will exit the zone setting mode. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Calibration Adjustment > Page 8720 Compass: Adjustments Vehicle Demagnetizing CAUTION: During demagnetizing, the demagnetizer Coil will be pulled 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. ^ 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. ^ 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 meter (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the roof and starting on the passenger side, demagnetize the front third of the roof closest to the windshield using a constant circular motion. Keep the circle's radius within 30 cm (12 in) while sweeping across the entire surface of the roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least away from the vehicle. 4 Turn the demagnetizer off. 2. Demagnetize the inside rear view mirror mounting pad. 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Using a circular motion, pass the demagnetizer over the outside of the windshield near the inside rear view mirror mounting pad. Without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 3 Turn the demagnetizer off. NOTE: The demagnetizer must be located over the outside of the windshield no greater than 2.5 cm (1 in). 3. Perform the compass zone adjustment procedure. See: Compass Zone Adjustment 4. Perform the calibration adjustment procedure. See: Compass Calibration Adjustment Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Page 8721 Compass: Service and Repair NOTE: The compass display and module are integral to the inside rear view mirror and not replaced separately. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedures 1. Disconnect the battery ground cable and wait at least one minute. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedures 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Install the passenger air bag module. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8728 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the vehicle battery connected? Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module (CNG) > Component Information > Description and Operation Fuel Gauge Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8733 Fuel Gauge Module (CNG): Testing and Inspection The Compressed Natural Gas fuel level indicator system is a function of the Natural Gas Vehicle (NGV) module. For Testing and Inspection procedures, Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8734 Fuel Gauge Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8735 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8736 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedures 1. Disconnect the battery ground cable and wait at least one minute. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedures 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Install the passenger air bag module. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8743 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the vehicle battery connected? Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Bulb > Component Information > Service and Repair Instrument Panel Bulb: Service and Repair REMOVAL 1. Remove the instrument cluster. 2. Remove the warning indicator bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Warning Switch <--> [Key Reminder Switch] > Component Information > Service and Repair Key Warning Switch: Service and Repair REMOVAL 1. Remove the ignition lock cylinder. 1 Insert the key into the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Release the clip. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure ^ Verify ignition lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation The low fuel warning indicator is controlled by the fuel indicator module and warns the driver when the fuel level is one-eighth or lower in the tank. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation SERVICE ENGINE SOON Your vehicle is equipped with a computer that monitors the engine's emission control system. This is commonly known as the On Board Diagnostic System (OBD II). This OBD II system protects the environment by ensuring that your vehicle continues to meet government emission standards. The OBD II system also assists the service technician in properly servicing your vehicle. The SERVICE ENGINE SOON indicator light illuminates when the ignition is first turned to the ON position to check the bulb. If it comes on after the engine is started, on of the engine's emission control systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will ususally be drivable and will not require towing. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 8756 Maintenance Required Lamp/Indicator: Service and Repair Solid SERVICE ENGINE SOON light This means that the On Board Diagnostic System (OBD II) has detected a malfunction. Temporary malfunctions may cause your SERVICE ENGINE SOON light to illuminate. Examples are: 1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or water in the fuel. 3. The fuel cap may not have been properly installed and securely tightened. The temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or properly installing and securely tightening the gas cap. After three driving cycles with out these or any other temporary malfunctions present, the SERVICE ENGINE SOON light should turn off. (A driving cycle consists of a cold engine start-up followed by mixed city/highway driving.) No additional vehicle service is required. Blinking SERVICE ENGINE SOON light Engine misfire is occurring which could cause damage to your catalytic converter. You should drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced at the first available opportunity. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation The speedometer and odometer provides speed information based on a speed/distance pulse signal from the Vehicle Speed Sensor (VSS). The VSS is mounted on the speedometer driven gear in the transmission. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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 NOTE : This vehicle is not equipped with an CHANGE OIL SOON or OIL CHANGE REQUIRED indicator. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Engine Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Engine Oil Pressure Switch: Locations 1. Oil Pressure Sensor 2. Oil Pressure Sensor Connector Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Engine Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Page 8766 Engine Oil Pressure Switch: Service and Repair Removal 1. Remove the oil pressure sensor oil pressure sensor: 1 Disconnect the wire. 2 Remove the oil pressure sensor. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation The low oil pressure warning indicator illuminates when the oil pressure switch opens, indicating oil pressure that is below the normal range. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the automatic transmission. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module Audible Warning Device Control Module: Diagrams Lighting Control Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module > Page 8778 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module > Page 8779 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) > Component Information > Description and Operation Fuel Gauge Module (CNG): Description and Operation The NGV module assembly: ^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers. ^ houses the unique electronics required for natural gas fuel systems. ^ is located on the center radiator support, behind the radiator grille. The NGV module carries out the following functions: ^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids. NOTE: No injector calculations are carried out; the injector driver output is not determined by the NGV module. ^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to calculate the density of the fuel; a look-up table is used to determine the output signal to the low fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge located in the instrument cluster. ^ power and ground supply: the NGV module supplies power to the instrument cluster components on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH). Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator - CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL]) - speedometer - temperature gauge - oil pressure gauge - Anti-lock Braking System (ABS) indicator - overdrive (OD) OFF indicator - brake warning indicator - AIR BAG warning indicator - fail-safe cooling indicator Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^ contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure. ^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi). ^ is located in the upper tank vent box on the upper tank rack. Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^ change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding temperature increases, the resistance decreases (the voltage signal also decreases). ^ provides a signal to the NGV module that indicates the temperature of the fuel ^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8783 Fuel Gauge Module (CNG): Testing and Inspection The Compressed Natural Gas fuel level indicator system is a function of the Natural Gas Vehicle (NGV) module. For Testing and Inspection procedures, Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8784 Fuel Gauge Module (CNG): Service and Repair REMOVAL WARNING ^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS, AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE. ^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. 1. Disconnect the battery ground cable. 2. Remove the upper radiator sight shield. 3. Remove the Natural Gas Vehicle (NGV) module harness connector cover. 4. Remove the NGV module electrical connector. 1 Loosen the NGV module electrical connector bolt. 2 Disconnect the NGV module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8785 5. Remove the NGV module and bracket assembly. 1 Remove the bolts. 2 Remove the NGV module and bracket assembly. 6. Remove the NGV module bracket assembly screws. 7. Remove the NGV module. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8786 1. To install, reverse the removal procedure. ^ Be sure to install the NGV module harness connector cover to prevent water from entering the NGV module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fasten Belts Indicator <--> [Seat Belt Reminder Lamp] > Component Information > Description and Operation Fasten Belts Indicator: Description and Operation The safety belt indicator is directly hardwired to the Lighting Control Module (LCM). The LCM controls the safety belt indicator depending on the signal it receives from the safety belt buckle switch. The safety belt indicator illuminates when the safety belt is not buckled, closing the safety belt buckle switch. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Warning Switch <--> [Key Reminder Switch] > Component Information > Service and Repair Key Warning Switch: Service and Repair REMOVAL 1. Remove the ignition lock cylinder. 1 Insert the key into the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Release the clip. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure ^ Verify ignition lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission range selector lever in the OD position. ^ Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (OD position). 3. Hang a 1.36 Kg (3 lbs.) weight on the range selector lever. 4. Center the pointer in the middle of the OD position. ^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 1.36 Kg (3 lbs.) weight. 6. Carefully move the shift range selector lever from detent to detent and compare with transmission settings. ^ Re-adjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation The speedometer and odometer provides speed information based on a speed/distance pulse signal from the Vehicle Speed Sensor (VSS). The VSS is mounted on the speedometer driven gear in the transmission. The signal sent to the Speedometer / odometer is affected by various factors and combinations such as: - Tire size - Gear ratio - Number of teeth on the VSS driven gear The allowable acceptable variations for indicated vehicle speed are: Speedometer/Odometer Value Indicated ................................................................................................................................................ Allowable Range 48 km/h (30 mph) Actual Speed ...................................................................................................................................................... 45-56 km/h (28-35 mph) 97 km/h (30 mph) Actual Speed ..................................................................................................................................................... 93-104 lm/h (58-65 mph) Odometer Measures Over Actual 16 km (10 Miles) Distance ................................................................................................. 15.4-16.6 km (9.6-10.3 miles) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Suspension Warning Indicator > Component Information > Description and Operation Suspension Warning Indicator: Description and Operation The CHECK AIR SUSPENSION warning indicator illuminates when a concern in the air suspension system is detected or when the air suspension switch is in the OFF position. During prove-out, when a concern is detected or the air suspension switch is OFF, an audible tone will sound and the CHECK AIR SUSPENSION warning indicator will flash on and off for five seconds. The CHECK AIR SUSPENSION warning indicator will then remain illuminated until the concern is corrected or the air suspension switch is switched ON. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation The engine coolant temperature gauge indicates the engine coolant temperature based on the operating resistance range from the engine coolant temperature sender. If the engine coolant temperature is low, the sender resistance is high. If the engine coolant temperature is high, the sender resistance is low. The engine coolant temperature sender resistance range should be between 9.7 ohms and 74 ohms. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Service and Repair Engine Coolant Temperature Sender: Service and Repair Removal CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange). 1. Partially drain the engine cooling system. 2. Remove the water temperature indicator sender unit. 1 Disconnect the electrical connector. 2 Remove the water temperature indicator sender unit. Installation 1. Install the water temperature indicator sender unit. 1 Install the water temperature indicator sender unit. 2 Connect the electrical connector. 2. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation Traction Control Indicator Lamp: Description and Operation The traction control indicator is located in the indicator lamp module and illuminates when the traction control system is disabled. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 8816 Ambient Light Sensor: Service and Repair REMOVAL 1. Unclip the instrument panel upper finish panel. 2. Disconnect the light sensor amplifier electrical connector. CAUTION: To avoid damaging the light sensor amplifier electrical connector, carefully tilt the panel to expose the connector without stretching the wiring. 3. Unclip the light sensor amplifier. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 8829 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 8835 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8838 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8839 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8840 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8841 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8842 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8843 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8844 Brake Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8845 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8846 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8847 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8848 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8849 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8850 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8851 Brake Lamp: Electrical Diagrams Diagram 90-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8852 Diagram 90-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8853 Diagram 90-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8854 Diagram 90-4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 8855 Brake Lamp: Description and Operation PRINCIPLES OF OPERATION NOTE: The stoplamps are powered from the Brake Pedal Position (BPP) switch directly, not from the Lighting Control Module (LCM). Stoplamps Stoplamps are mounted in the same housings as the rear lamp. Stoplamp functions are carried out by double filament bulbs. The low power filaments are dedicated to the parking lamp operation. Stoplamps utilize the high power filaments when the driver applies the brake pedal, closing the BPP switch. Power is routed from the BPP switch directly to the stoplamps. High Mounted Stoplamp The high mounted stoplamp is mounted in the rear window area. It operates in conjunction with the stoplamps. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Brake Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged Brake Pedal Position (BPP) switch Electrical ^ Blown Central Junction Box (CJB) Fuse 1(15 A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged stoplamp bulb(s) ^ Damaged BPP switch 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8858 Brake Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged Brake Pedal Position (BPP) switch Electrical ^ Blown Central Junction Box (CJB) Fuse 1(15 A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged stoplamp bulb(s) ^ Damaged BPP switch 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8859 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8860 Brake Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8861 K1 - K2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8862 K3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8863 L1 - L2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8864 M1 - M2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 8865 Brake Lamp: Service and Repair REMOVAL 1. Remove the two high mounted stoplamp screws. 2. Remove the high mounted stoplamp assembly. 1 Disconnect the electrical connector. 2 Depress the clips and remove the high mounted stoplamp assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 8866 73 Digital Multimeter Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 8875 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 8881 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8882 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8883 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove LH instrument panel insulator. 1 Remove the pin-type retainers. 2 Remove the LH instrument panel insulator. ^ Disconnect the courtesy lamp. 3. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 4. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the (A) BPP switch from the (B) brake master cylinder push rod. 3 Remove the brake master cylinder push rod spacer. 4 Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Customer Interest for High Mounted Stop Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling High Mounted Stop Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Customer Interest for High Mounted Stop Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 8892 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stop Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling High Mounted Stop Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stop Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 8898 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions Cornering Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8903 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8904 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8905 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8906 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8907 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8908 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8909 Cornering Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8910 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8911 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8912 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8913 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8914 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8915 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8916 Diagram 91-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Page 8917 Cornering Lamp: Description and Operation PRINCIPLES OF OPERATION The cornering lamps are powered from the turn signal circuit. When the multifunction switch is activated and the headlamps are on, the cornering lamp on the turn side will illuminate, and remain illuminated until the turn signal cancels. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Cornering Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch Electrical ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for lighting control module (LCM), go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8920 Cornering Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch Electrical ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for lighting control module (LCM), go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8921 Cornering Lamp: Diagnostic Trouble Code Descriptions Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8922 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8923 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8924 Cornering Lamp: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch Electrical ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for lighting control module (LCM), go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch Electrical ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for lighting control module (LCM), go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8925 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8926 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8927 Icons Used With Pinpoint Tests Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8928 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8929 N1 - N2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8930 O1 - O4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8931 P1 - P2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8932 P3 - P4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8933 Q1 R1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8934 S1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8935 T1 U1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8936 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Page 8937 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8942 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8943 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8944 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8945 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8946 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8947 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8948 Courtesy Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8949 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8950 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8951 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8952 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8953 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8954 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8955 Courtesy Lamp: Electrical Diagrams Diagram 89-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8956 Diagram 89-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8957 Diagram 89-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8958 Diagram 89-4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Module Bolt 27 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 8963 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 8964 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Remove the battery ground cable. 2. Remove the sight shield. ^ Twist the clips. 3. Remove the Daytime Running Lamps (DRL) module 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the DRL module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > Customer Interest for Dome Lamp: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging Dome Lamp: Customer Interest Dome Lamp/Headliner - Sagging Article No. 99-20-8 10/04/99 INTERIOR - HEADLINER SAGS - VEHICLES BUILT 12/1998 THROUGH 9/1999 FORD: 1999-2000 CROWN VICTORIA MERCURY: 1999-2000 GRAND MARQUIS ISSUE The interior dome lamp may not be adhered to the roof on some vehicles. This may be caused by the headliner material which was revised in the 1999 model to a less rigid material. During assembly in hot/humid conditions, the dome lamp may sag and lose contact with the roof sheet metal prior to the adhesive curing. ACTION Remove the interior dome lamp mounting bracket. Clean any residual adhesive from roof sheet metal. Install new mounting bracket with two-sided foam tape. This should provide an adhesive attachment between the headliner and roof sheet metal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the dome lamp lens. 2. Remove screws that secure the lamp assembly to the mounting bracket. 3. Disconnect the electrical connector to the lamp assembly. 4. Remove the black mounting bracket through the hole in the headliner. 5. Clean any adhesive from the roof sheet metal above the opening in the headliner. Use a putty knife to scrape off the adhesive. 6. Remove the plastic film from the foam tape on the back of the new mounting bracket. The adhesive should now be exposed. 7. Locate and align the new mounting bracket to the headliner opening. NOTE THE TWO (2) LONG LOCATOR PINS ARE AT THE REAR SIDE OF THE OPENING. 8. Push the mounting bracket and headliner up against the roof. NOTE: SIMULTANEOUSLY PUSH THE MOUNTING BRACKET AND HEADLINER UP TO ENSURE THE BRACKET STAYS CORRECTLY LOCATED. 9. Connect electrical connector to the lamp assembly. 10. Locate the lamp assembly to the mounting bracket. Tighten screws. 11. Install dome lamp lens. PART NUMBER PART NAME F3MZ-5451 536-BA Bracket - Single Light F5AZ-5451 536-BA Bracket - Dual Beam Light OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > Customer Interest for Dome Lamp: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging > Page 8973 OPERATION DESCRIPTION TIME 992008A Install New Headliner 0.3 Hr. Bracket DEALER CODING CONDITION BASIC PART NO. CODE 5451536 33 OASIS CODES: 105000, 107000, 201100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Dome Lamp: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging Dome Lamp: All Technical Service Bulletins Dome Lamp/Headliner - Sagging Article No. 99-20-8 10/04/99 INTERIOR - HEADLINER SAGS - VEHICLES BUILT 12/1998 THROUGH 9/1999 FORD: 1999-2000 CROWN VICTORIA MERCURY: 1999-2000 GRAND MARQUIS ISSUE The interior dome lamp may not be adhered to the roof on some vehicles. This may be caused by the headliner material which was revised in the 1999 model to a less rigid material. During assembly in hot/humid conditions, the dome lamp may sag and lose contact with the roof sheet metal prior to the adhesive curing. ACTION Remove the interior dome lamp mounting bracket. Clean any residual adhesive from roof sheet metal. Install new mounting bracket with two-sided foam tape. This should provide an adhesive attachment between the headliner and roof sheet metal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the dome lamp lens. 2. Remove screws that secure the lamp assembly to the mounting bracket. 3. Disconnect the electrical connector to the lamp assembly. 4. Remove the black mounting bracket through the hole in the headliner. 5. Clean any adhesive from the roof sheet metal above the opening in the headliner. Use a putty knife to scrape off the adhesive. 6. Remove the plastic film from the foam tape on the back of the new mounting bracket. The adhesive should now be exposed. 7. Locate and align the new mounting bracket to the headliner opening. NOTE THE TWO (2) LONG LOCATOR PINS ARE AT THE REAR SIDE OF THE OPENING. 8. Push the mounting bracket and headliner up against the roof. NOTE: SIMULTANEOUSLY PUSH THE MOUNTING BRACKET AND HEADLINER UP TO ENSURE THE BRACKET STAYS CORRECTLY LOCATED. 9. Connect electrical connector to the lamp assembly. 10. Locate the lamp assembly to the mounting bracket. Tighten screws. 11. Install dome lamp lens. PART NUMBER PART NAME F3MZ-5451 536-BA Bracket - Single Light F5AZ-5451 536-BA Bracket - Dual Beam Light OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Dome Lamp: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging > Page 8979 OPERATION DESCRIPTION TIME 992008A Install New Headliner 0.3 Hr. Bracket DEALER CODING CONDITION BASIC PART NO. CODE 5451536 33 OASIS CODES: 105000, 107000, 201100 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > Page 8980 Dome Lamp: Service and Repair REMOVAL 1. Carefully release the dome lamp lens. 2. Remove the three screws. 3. Remove the dome/map lamp assembly. ^ Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing Exterior Lighting Module: Customer Interest Turn Signals - Intermittent Rapid Flashing Article No. 02-9-7 05/13/02 ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY FORD: 1998-2002 CROWN VICTORIA MERCURY: 1998-2002 GRAND MARQUIS This article is being republished in its entirety to update the Service Procedure and to update the parts required. ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn signal fast flash is not due to bulb outage, then verify good continuity at all ground screws. ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part. Refer to the following Service Procedure for details. SERVICE PROCEDURE If normal diagnostics does not correct the condition, replace the Lighting Control Module with the latest engineering level as follows: 1 Disconnect the battery ground cable. For additional information refer to Workshop Manual Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year. 2. Remove the LH instrument panel lower insulator (Figure 1). a. Remove the pin-type retainers (Figure 1, Detail 1). b. Disconnect the courtesy lamp (Figure 1, Detail 2). 3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and shaft. For additional information, refer to Section 310-02 of the Workshop Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 8989 4. Position the LCM aside. a. Remove the screws (Figure 2, Detail 1). b. Release the locking tab (Figure 2, Detail 2). 5. Disconnect the electrical connectors and remove the LCM (Figure 3). 6. To install, reverse the removal procedure. Check for correct operation. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-21-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 8990 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing Exterior Lighting Module: All Technical Service Bulletins Turn Signals - Intermittent Rapid Flashing Article No. 02-9-7 05/13/02 ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY FORD: 1998-2002 CROWN VICTORIA MERCURY: 1998-2002 GRAND MARQUIS This article is being republished in its entirety to update the Service Procedure and to update the parts required. ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn signal fast flash is not due to bulb outage, then verify good continuity at all ground screws. ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part. Refer to the following Service Procedure for details. SERVICE PROCEDURE If normal diagnostics does not correct the condition, replace the Lighting Control Module with the latest engineering level as follows: 1 Disconnect the battery ground cable. For additional information refer to Workshop Manual Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year. 2. Remove the LH instrument panel lower insulator (Figure 1). a. Remove the pin-type retainers (Figure 1, Detail 1). b. Disconnect the courtesy lamp (Figure 1, Detail 2). 3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and shaft. For additional information, refer to Section 310-02 of the Workshop Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 8996 4. Position the LCM aside. a. Remove the screws (Figure 2, Detail 1). b. Release the locking tab (Figure 2, Detail 2). 5. Disconnect the electrical connectors and remove the LCM (Figure 3). 6. To install, reverse the removal procedure. Check for correct operation. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-21-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 8997 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1 > Page 9003 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Hazard Flasher Hazard Warning Flasher: Locations Hazard Flasher Instrument Panel View 1996 Crown Victoria shown, others similar The Hazard Flasher output is provided by the Lighting Control Module, which is located behind LH side of the instrument panel. There are no separate relays for Hazard Flasher output aside from the LCM. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Hazard Flasher > Page 9008 Hazard Warning Flasher: Locations Police Option Only Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Hazard Flasher > Page 9009 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Indicator > Component Information > Description and Operation Hazard Warning Indicator: Description and Operation The LH and/or RH turn indicators will flash when the multifunction switch is placed in the RH or LH turn signal ON position or when the hazard switch is placed in the ON position and the ignition is ON. If the hazard switch is on and the ignition is OFF, only the hazard indicator in the indicator lamp module will flash. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 9016 Hazard Warning Switch: Description and Operation PRINCIPLES OF OPERATION The hazard flasher switch (part of the multifunction switch) is located on the top of the steering column, forward of the steering wheel. ^ The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the switch top. ^ The switch should produce an audible click when it toggles from one state to another. ^ The switch should extend markedly further above the column when the switch is ON than it does when it is OFF. When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the two turn indicators in the instrument cluster will flash simultaneously. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Component Test Hazard Warning Switch: Testing and Inspection Component Test Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Component Test > Page 9019 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Component Test > Page 9020 Hazard Warning Switch: Testing and Inspection Operational Test The hazard flasher switch (part of the multifunction switch) is located on the top of the steering column, forward of the steering wheel. - The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the switch top. - The switch should produce an audible click when it toggles from one state to another. - The switch should extend markedly further above the column when the switch is ON than it does when it is OFF. When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the two turn indicators in the instrument cluster will flash simultaneously. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 9021 Hazard Warning Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 9022 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 9023 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Specifications Headlamp Bulb: Specifications Low Beam 4.30 A 55 W High Beam 5.08 A 65 W Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Specifications > Page 9028 Headlamp Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN 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. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement 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 the headlamps on with the bulb removed. 1. Remove the headlamp assembly. 2. Rotate the headlamp bulb retainer counterclockwise and remove. - Grasp the headlamp bulb by its base and remove the bulb. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE HALOGEN 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9032 Headlamp Dimmer Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9033 Headlamp Dimmer Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9034 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9035 Headlamp Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9036 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9037 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Main Light Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9041 Main Light Switch: Description and Operation The headlamp switch is a multi-position switch. ^ The positions include OFF, PARK, and HEAD. ^ With the headlamp switch in the PARK position (first detent), a signal is supplied to the LCM which powers the front parking lamps, the tail lamps, the side marker lamps, and the license lamp. ^ With the headlamp switch in the HEAD position, power is supplied to the headlamps through the LCM and the multifunction switch. ^ The panel dim switch (part of the headlamp switch) is located above the headlamp switch. The panel dim switch operates only with the parking lamps or headlamps on. ^ When the panel dim switch is held in the up position, the instrument panel lighting will progressively brighten. ^ When the panel dim switch is held in the down position, the instrument panel lighting will progressively dim. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9042 Main Light Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9043 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9044 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9045 Main Light Switch: Service and Repair REMOVAL 1. Remove the instrument panel cluster finish panel. 2. Remove the headlamp switch. ^ Unclip the switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Hi-Beam Indicator <--> [Hi-Beam Indicator Lamp] > Component Information > Description and Operation Hi-Beam Indicator: Description and Operation The high beam indicator will illuminate when the multifunction switch is placed in the high beam headlamps ON position or the flash-to-pass position. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9053 Horn Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9054 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL AND INSTALLATION NOTE: The horn switch is integral to the driver side air bag module and cannot be replaced separately. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9062 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9063 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9064 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9065 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9066 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9067 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9068 Interior Lighting Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9069 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9070 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9071 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9072 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9073 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9074 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9075 Interior Lighting Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9076 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9077 Interior Lighting Module: Electrical Diagrams Diagram 58-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9078 Diagram 58-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9079 Diagram 58-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Lamp Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9084 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9085 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9086 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9087 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9088 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9089 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9090 Lamp Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9091 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9092 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9093 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9094 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9095 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9096 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9097 Lamp Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9098 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9099 Lamp Control Module: Electrical Diagrams Diagram 58-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9100 Diagram 58-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9101 Diagram 58-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 9102 Lamp Control Module: Description and Operation The Lighting Control Module (LCM) eliminates the electronic interference and heat associated with the thermoelectric devices used previously. The LCM is a microprocessor based module that controls several vehicle subsystems. It responds to electrical signals from various switches, sensors, and external modules. LCM subsystem function include: ^ headlamps with autolamps ^ turn signal lamps/hazard flasher lamps ^ cornering lamps ^ parking lamps ^ courtesy lamps ^ demand lamps ^ battery saver ^ backlighting ^ interfacing with the driver door module via SCP for illuminated entry. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 9103 Lamp Control Module: Service and Repair REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH instrument panel lower insulator. 1 Remove the pin-type retainers. 2 Disconnect the courtesy lamp. 3 Remove the LH instrument panel insulator. 3. Position the LCM aside. 1 Remove the locking tab. 2 Release the locking tab. 3 Position the LCM aside. 4. Remove the LCM. 1 Disconnect the electrical connectors. 2 Remove the LCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 9104 CAUTION: Once the new module is installed, it is necessary to download the module configuration information from New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9109 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9110 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9111 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9112 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9113 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9114 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9115 License Plate Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9116 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9117 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9118 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9119 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9120 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9121 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9122 License Plate Lamp: Electrical Diagrams Diagram 92-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9123 Diagram 92-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9124 Diagram 92-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9125 Diagram 92-4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 9126 License Plate Lamp: Description and Operation PRINCIPLES OF OPERATION The power to these lamps is provided through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis License Plate Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15 A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9129 License Plate Lamp: Initial Inspection and Diagnostic Overview Inspection and Verification (Start Testing Here) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15 A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Principles of Operation (How Does It Work?) The license lamps have replaceable miniature bulbs and are provided power through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTOLAMP positions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9130 License Plate Lamp: Diagnostic Trouble Code Descriptions LCM Diagnostic Trouble Code Index Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9131 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9132 Part 3 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9133 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9134 License Plate Lamp: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15 A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Inspection and Verification (Start Testing Here) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15 A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9135 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Principles of Operation (How Does It Work?) The license lamps have replaceable miniature bulbs and are provided power through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTOLAMP positions. LCM Diagnostic Trouble Code Index Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9136 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9137 Part 3 Of 3 Icons Used With Pinpoint Tests Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9138 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9139 V1 - V3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9140 V4 W1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9141 W2 - W4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9142 X1 - X3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9143 Y1 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9144 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Page 9145 License Plate Lamp: Tools and Equipment Special Tools Used While Performing Tests Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9150 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9151 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9152 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9153 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9154 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9155 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9156 Marker Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9157 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9158 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9159 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9160 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9161 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9162 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9163 Marker Lamp: Electrical Diagrams Diagram 92-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9164 Diagram 92-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9165 Diagram 92-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9166 Diagram 92-4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 9167 Marker Lamp: Description and Operation PRINCIPLES OF OPERATION The power to these lamps is provided through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Marker Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9170 Marker Lamp: Initial Inspection and Diagnostic Overview Inspection and Verification (Start Testing Here) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Principles of Operation (How Does It Work?) The power to these lamps is provided through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9171 Marker Lamp: Diagnostic Trouble Code Descriptions LCM Diagnostic Trouble Code Index Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9172 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9173 Part 3 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9174 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9175 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9176 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9177 Marker Lamp: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Inspection and Verification (Start Testing Here) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9178 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Principles of Operation (How Does It Work?) The power to these lamps is provided through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions. LCM Diagnostic Trouble Code Index Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9179 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9180 Part 3 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9181 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9182 Icons Used With Pinpoint Tests Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9183 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9184 V1 - V3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9185 V4 W1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9186 W2 - W4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9187 X1 - X3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9188 Y1 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Page 9189 Marker Lamp: Service and Repair REMOVAL 1. Remove the sight shield. ^ Twist the clips. 2. Remove the screw. 3. From inside the engine compartment, remove the nut. Grand Marquis shown, Crown Victoria Similar 4. Remove the side marker lamp assembly. ^ Disconnect the electrical connector(s). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Page 9190 ^ If necessary, install new bulb(s). INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9195 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9196 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9197 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9198 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9199 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9200 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9201 Parking Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9202 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9203 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9204 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9205 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9206 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9207 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9208 Parking Lamp: Electrical Diagrams Diagram 92-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9209 Diagram 92-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9210 Diagram 92-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9211 Diagram 92-4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 9212 Parking Lamp: Description and Operation PRINCIPLES OF OPERATION The power to these lamps is provided through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Parking Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code (DTC) Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9215 Parking Lamp: Initial Inspection and Diagnostic Overview Principles of Operation (How Does It Work?) The power to these lamps is provided through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions. Inspections and Verification (Start Testing Here) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code (DTC) Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9216 Parking Lamp: Diagnostic Trouble Code Descriptions LCM Diagnostic Trouble Code (DTC) Index Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9217 Part 2 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9218 Part 3 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9219 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9220 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9221 Parking Lamp: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code (DTC) Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Principles of Operation (How Does It Work?) The power to these lamps is provided through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions. Inspections and Verification (Start Testing Here) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9222 ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code (DTC) Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures LCM Diagnostic Trouble Code (DTC) Index Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9223 Part 2 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9224 Part 3 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9225 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9226 Icons Used With Pinpoint Tests Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9227 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9228 V1 - V3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9229 V4 W1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9230 W2 - W4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9231 X1 - X3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9232 Y1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Module Bolt 27 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 9237 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 9238 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Remove the battery ground cable. 2. Remove the sight shield. ^ Twist the clips. 3. Remove the Daytime Running Lamps (DRL) module 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the DRL module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing Exterior Lighting Module: Customer Interest Turn Signals - Intermittent Rapid Flashing Article No. 02-9-7 05/13/02 ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY FORD: 1998-2002 CROWN VICTORIA MERCURY: 1998-2002 GRAND MARQUIS This article is being republished in its entirety to update the Service Procedure and to update the parts required. ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn signal fast flash is not due to bulb outage, then verify good continuity at all ground screws. ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part. Refer to the following Service Procedure for details. SERVICE PROCEDURE If normal diagnostics does not correct the condition, replace the Lighting Control Module with the latest engineering level as follows: 1 Disconnect the battery ground cable. For additional information refer to Workshop Manual Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year. 2. Remove the LH instrument panel lower insulator (Figure 1). a. Remove the pin-type retainers (Figure 1, Detail 1). b. Disconnect the courtesy lamp (Figure 1, Detail 2). 3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and shaft. For additional information, refer to Section 310-02 of the Workshop Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 9247 4. Position the LCM aside. a. Remove the screws (Figure 2, Detail 1). b. Release the locking tab (Figure 2, Detail 2). 5. Disconnect the electrical connectors and remove the LCM (Figure 3). 6. To install, reverse the removal procedure. Check for correct operation. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-21-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 9248 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing Exterior Lighting Module: All Technical Service Bulletins Turn Signals - Intermittent Rapid Flashing Article No. 02-9-7 05/13/02 ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY FORD: 1998-2002 CROWN VICTORIA MERCURY: 1998-2002 GRAND MARQUIS This article is being republished in its entirety to update the Service Procedure and to update the parts required. ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn signal fast flash is not due to bulb outage, then verify good continuity at all ground screws. ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part. Refer to the following Service Procedure for details. SERVICE PROCEDURE If normal diagnostics does not correct the condition, replace the Lighting Control Module with the latest engineering level as follows: 1 Disconnect the battery ground cable. For additional information refer to Workshop Manual Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year. 2. Remove the LH instrument panel lower insulator (Figure 1). a. Remove the pin-type retainers (Figure 1, Detail 1). b. Disconnect the courtesy lamp (Figure 1, Detail 2). 3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and shaft. For additional information, refer to Section 310-02 of the Workshop Manual. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 9254 4. Position the LCM aside. a. Remove the screws (Figure 2, Detail 1). b. Release the locking tab (Figure 2, Detail 2). 5. Disconnect the electrical connectors and remove the LCM (Figure 3). 6. To install, reverse the removal procedure. Check for correct operation. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-21-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 9255 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1 > Page 9260 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 9264 Horn Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 9265 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9270 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9271 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9272 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9273 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9274 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9275 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9276 Interior Lighting Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9277 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9278 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9279 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9280 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9281 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9282 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9283 Interior Lighting Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9284 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9285 Interior Lighting Module: Electrical Diagrams Diagram 58-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9286 Diagram 58-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9287 Diagram 58-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Lamp Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9292 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9293 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9294 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9295 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9296 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9297 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9298 Lamp Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9299 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9300 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9301 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9302 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9303 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9304 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9305 Lamp Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9306 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9307 Lamp Control Module: Electrical Diagrams Diagram 58-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9308 Diagram 58-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9309 Diagram 58-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 9310 Lamp Control Module: Description and Operation The Lighting Control Module (LCM) eliminates the electronic interference and heat associated with the thermoelectric devices used previously. The LCM is a microprocessor based module that controls several vehicle subsystems. It responds to electrical signals from various switches, sensors, and external modules. LCM subsystem function include: ^ headlamps with autolamps ^ turn signal lamps/hazard flasher lamps ^ cornering lamps ^ parking lamps ^ courtesy lamps ^ demand lamps ^ battery saver ^ backlighting ^ interfacing with the driver door module via SCP for illuminated entry. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 9311 Lamp Control Module: Service and Repair REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH instrument panel lower insulator. 1 Remove the pin-type retainers. 2 Disconnect the courtesy lamp. 3 Remove the LH instrument panel insulator. 3. Position the LCM aside. 1 Remove the locking tab. 2 Release the locking tab. 3 Position the LCM aside. 4. Remove the LCM. 1 Disconnect the electrical connectors. 2 Remove the LCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 9312 CAUTION: Once the new module is installed, it is necessary to download the module configuration information from New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 9317 Ambient Light Sensor: Service and Repair REMOVAL 1. Unclip the instrument panel upper finish panel. 2. Disconnect the light sensor amplifier electrical connector. CAUTION: To avoid damaging the light sensor amplifier electrical connector, carefully tilt the panel to expose the connector without stretching the wiring. 3. Unclip the light sensor amplifier. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 9329 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative Technical Service Bulletin # 02-13-6 Date: 020708 Stoplamps/Shift Interlock - Inoperative Article No. 02-13-6 07/08/02 ^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR ^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR FORD: 1998-2002 CROWN VICTORIA LINCOLN: 1998-2002 TOWN CAR MERCURY: 1998-2002 GRAND MARQUIS ISSUE The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be caused by a deformed Brake Pedal Position Switch electrical connector. ACTION Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail. Refer to the following Service procedure for details. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021306A Replace Brake Pedal 0.4 Hr. Position Switch Electrical Connector DEALER CODING CONDITION BASIC PART NO. CODE 14A005 01 OASIS CODES: 201000, 201200, 203000, 203200, 503300 Service Procedure 1. Verify the condition. 2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) 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: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 9335 3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation. Refer to Wiring Diagrams, Section 90 for additional details. 4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic information. 5. If deformation is found, continue with the following procedure. 6. Disconnect the battery ground cable. 7. Disconnect the Brake Pedal Position Switch electrical connector. 8. Remove the deformed connector by cutting off 4 inches of wire from the harness. 9. Strip approximately 1/4" from the remaining harness and twist the end of each wire. 10. Obtain the repair kit part number 2W1Z-14A411-AAA. 11. The repair kit pigtail wiring comes in 1 piece with connectors. 12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire. 13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with red strip with LG/RD). 14. Use crimp connectors that are found in the repair kit. 15. Evenly position the crimp connectors over the wire repair. 16. To crimp the connectors, use the proper wire crimp tool. 17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink. 18. Reconnect the Brake Pedal Position Switch. 19. Replace the LH instrument panel insulator. 20. Reconnect battery ground cable. 21. Test and verify the Brake Pedal Position Switch operates properly. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 9336 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 9337 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove LH instrument panel insulator. 1 Remove the pin-type retainers. 2 Remove the LH instrument panel insulator. ^ Disconnect the courtesy lamp. 3. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 4. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the (A) BPP switch from the (B) brake master cylinder push rod. 3 Remove the brake master cylinder push rod spacer. 4 Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 9341 Hazard Warning Switch: Description and Operation PRINCIPLES OF OPERATION The hazard flasher switch (part of the multifunction switch) is located on the top of the steering column, forward of the steering wheel. ^ The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the switch top. ^ The switch should produce an audible click when it toggles from one state to another. ^ The switch should extend markedly further above the column when the switch is ON than it does when it is OFF. When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the two turn indicators in the instrument cluster will flash simultaneously. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Component Test Hazard Warning Switch: Testing and Inspection Component Test Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Component Test > Page 9344 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Component Test > Page 9345 Hazard Warning Switch: Testing and Inspection Operational Test The hazard flasher switch (part of the multifunction switch) is located on the top of the steering column, forward of the steering wheel. - The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the switch top. - The switch should produce an audible click when it toggles from one state to another. - The switch should extend markedly further above the column when the switch is ON than it does when it is OFF. When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the two turn indicators in the instrument cluster will flash simultaneously. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 9346 Hazard Warning Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 9347 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 9348 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9352 Headlamp Dimmer Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9353 Headlamp Dimmer Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9354 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9355 Headlamp Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9356 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9357 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Main Light Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9361 Main Light Switch: Description and Operation The headlamp switch is a multi-position switch. ^ The positions include OFF, PARK, and HEAD. ^ With the headlamp switch in the PARK position (first detent), a signal is supplied to the LCM which powers the front parking lamps, the tail lamps, the side marker lamps, and the license lamp. ^ With the headlamp switch in the HEAD position, power is supplied to the headlamps through the LCM and the multifunction switch. ^ The panel dim switch (part of the headlamp switch) is located above the headlamp switch. The panel dim switch operates only with the parking lamps or headlamps on. ^ When the panel dim switch is held in the up position, the instrument panel lighting will progressively brighten. ^ When the panel dim switch is held in the down position, the instrument panel lighting will progressively dim. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9362 Main Light Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9363 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9364 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9365 Main Light Switch: Service and Repair REMOVAL 1. Remove the instrument panel cluster finish panel. 2. Remove the headlamp switch. ^ Unclip the switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL AND INSTALLATION NOTE: The horn switch is integral to the driver side air bag module and cannot be replaced separately. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams Multifunction Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9372 Multifunction Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9373 Multifunction Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9374 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9375 Multifunction Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9376 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9377 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications Tail Lamp: Specifications Rear Lamp Nuts 18 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9387 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9388 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9389 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9390 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9391 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9392 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9393 Tail Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9394 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9395 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9396 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9397 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9398 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9399 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9400 Tail Lamp: Electrical Diagrams Diagram 92-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9401 Diagram 92-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9402 Diagram 92-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9403 Diagram 92-4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 9404 Tail Lamp: Description and Operation PRINCIPLES OF OPERATION The power to these lamps is provided through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Tail Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9407 Tail Lamp: Initial Inspection and Diagnostic Overview Inspection and Verification (Start Testing Here) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Principles of Operation (How Does It Work?) The power to these lamps is provided through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9408 Tail Lamp: Diagnostic Trouble Code Descriptions LCM Diagnostic Trouble Code Index Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9409 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9410 Part 3 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9411 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9412 Tail Lamp: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Inspection and Verification (Start Testing Here) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Headlamp switch Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (15A) ^ Damaged wiring harness ^ Loose or corroded connection ^ Damaged parking, rear or license bulb(s) ^ Damaged Lighting Control Module (LCM) 3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the LCM. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9413 7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index 8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Principles of Operation (How Does It Work?) The power to these lamps is provided through the Lighting Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions. LCM Diagnostic Trouble Code Index Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9414 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9415 Part 3 Of 3 Icons Used With Pinpoint Tests Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9416 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9417 V1 - V3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9418 V4 W1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9419 W2 - W4 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9420 X1 - X3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9421 Y1 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9422 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Page 9423 Tail Lamp: Service and Repair REMOVAL 1. Position the luggage compartment trim aside. ^ Remove the pin-type retainer. 2. Remove the rear lamp nuts. 3. Remove the rear lamp assembly and disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Instrument Panel View 1996 Crown Victoria shown, others similar The Turn Signal Flasher output is provided by the Lighting Control Module, which is located behind the LH side of the instrument panel. There are no separate relays for Turn Signal Flasher output aside from the LCM. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation The LH and/or RH turn indicators will flash when the multifunction switch is placed in the RH or LH turn signal ON position or when the hazard switch is placed in the ON position and the ignition is ON. If the hazard switch is on and the ignition is OFF, only the hazard indicator in the indicator lamp module will flash. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams Multifunction Switch: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9434 Multifunction Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9435 Multifunction Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9436 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9437 Multifunction Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9438 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 9439 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 9450 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 9451 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair Rear Defogger: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair TSB 04-24-5 12/13/04 REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria, Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005 Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape 2004-2005 F-150, Freestar 2005 Escape Hybrid LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego 1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 04-18-9 to update vehicle applications and service procedure. ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass. ACTION Follow the diagnostic and repair procedures included in this article to inspect and service rear defroster grid lines, integral antenna concerns or broken terminal tabs. SERVICE PROCEDURE Warrantable/Non Warrantable repairs Warrantable grid line repairs typically can be identified by one inoperative grid line with a small discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are scratched or have the silver material removed are not warrantable and should be addressed with the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated Back Lite Damageability Job Aid for additional information and examples of defects and damage. NOTE THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9459 THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS EXPLAINED IN THIS ARTICLE. Examples Of Non-Warrantable Grid Line Damage ^ Ice scraper damage to grid lines ^ Animal scratches on grid lines ^ Window tint film/removal of the film which damages grid lines ^ Stickers placed over grids which upon removal, removes the grid line material ^ License plate (steel type placed against the inside of back glass) which rubs on the grid line causing damage ^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal removes grid line material ^ Cargo or lumber rubbing against the glass which removes grid line material ^ Cellular phone antenna installation/removal which damages grid line material NOTE AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL ACROSS THEM. GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR 12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID LINE INOPERATIVE - DIAGNOSTICS 1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power and ground to the back-glass. 2. Connect a test lamp or DVOM to a good body ground. 3. Turn the ignition key to the run position and depress and release the rear defroster button to turn the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME THE DEFROSTER BUTTON IS PRESSED. 4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM + lead to each grid line. (Use caution not to damage grid lines). The DVOM should read approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test light, the bulb should be approximately the same brightness on each line from top to bottom. If the DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid line with the + test lead or test lamp until the voltage changes suddenly. This is the area of concern, use chalk to mark the area of concern and mark the outside of the glass at that same area. 5. Repair per the Grid Line Repair Procedure. GRID LINE REPAIR PROCEDURE NOTE LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE, HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE (5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID LINE AREAS. NOTE IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW DEFROSTER REPAIR COMPOUND. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9460 Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or equivalent meeting Ford specification ESB-M4J58-A as follows: Surface Preparation 1. Bring vehicle inside and warm it to 60° F (16° C) or above. 2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. NOTE THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME. Mixing The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake frequently during use. Application 1. Mark location of open grid on the outside of the back window glass (performed in diagnostics). Place protective covering over the package tray as necessary. 2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should be at the center of the mask and tape gap must be no wider than the existing grid line. Other types of tape may be used but end results of the repair may not appear as visually acceptable due to ease of application and tape edge finish. 3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five (5) minutes drying time between coats) across the open grid line area using the brush applicator in the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area. Apply a minimum of six (6) coats of the grid repair compound. 4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown lacquer touch-up paint across the open line area first. Take care to paint only the area missing the color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at least five (5) minutes between coats. Apply six (6) coats of grid repair compound. NOTE THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9461 TIME TO MATCH THE REST OF THE GRID. 5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step outside and inspect the repaired area. If the repair compound is visible above or below the grid, the excess can be removed. This may be done by placing a single-edge razor blade on the back window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better but may not be cosmetically appealing. CAUTION BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID LINES FUNCTION PROPERLY WHEN FINISHED. Curing The service coating will air-dry in approximately one (1) minute and the system can be energized after five minutes. Maximum hardness and adhesion occur after approximately 24 hours. SOLDER METHOD OF LEAD TERMINAL NOTE THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE. PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY. The new terminal will cover the original terminal location, but must be placed so that the new terminal conductive areas will be placed on a good conductive base. This area should be cleaned with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to improve appearance. CAUTION DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER. BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL. The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a visual indication when the terminal has reached the proper temperature to melt the solder on the terminal. When the proper temperature is achieved the temperature paint will liquefy and change color. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9462 Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus, use type B (Figure 3). NOTE DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL. SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE BUSS-BAR ON GOOD CONDUCTIVE MATERIAL. 1. Place the replacement terminal over the original tab location making sure the conductive areas of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original location which does not have conductive material (figure 4). 2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle may allow the terminal to slip when the solder liquefies). 3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab. Energize the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint color completely changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30) seconds. 4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for another two (2) minutes before the wiring lead is attached to the terminal. 5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify operation. Parts Block Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9463 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042405A Repair Grid Lines (Includes 0.7 Hr. Time To Diagnose And Recheck) 042405B Replace Terminal (Includes 0.4 Hr. Time To Diagnose And Recheck) 042405C Repair Grid Lines And 0.8 Hr. Replace Terminal (Includes Time To Diagnose And Recheck) DEALER CODING CONDITION BASIC PART NO. CODE 7042006 28 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9468 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9469 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions One Touch Window Down Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9474 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9475 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9476 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9477 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9478 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9479 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9480 One Touch Window Down Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9481 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9482 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9483 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9484 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9485 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9486 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9487 One Touch Window Down Module: Connector Views Driver Door Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9488 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9489 One Touch Window Down Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9490 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9491 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Page 9492 One Touch Window Down Module: Service and Repair REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door trim panel. 3. Remove the Driver Door Module (DDM). 1 Disconnect the electrical connector. 2 Remove the screws. 3. Release the locking tab. INSTALLATION CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 9501 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 9502 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 9503 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 9504 Power Window Switch: Description and Operation PRINCIPLES OF OPERATION The driver power window one touch down operation is controlled by the Driver Door Module (DDM), if equipped with remote keyless entry, or the one touch down module if not equipped with remote keyless entry. The one touch down operation is requested of the module by momentarily pressing the driver window down switch for 32 ms to 480 ms. The module uses the initial voltage input from the down switch to begin one touch down operation. If the voltage input was less than 480 ms, the module will maintain the voltage supply to the motor down circuit. Circuit breaker 14 (20 A) supplies the power to the module for this operation. The module will maintain the operation until: seven seconds expire. - the module detects motor stalled by monitoring the current draw. - a voltage input is received by the module on either the up or down switch circuits. The ground for one touch down operation does not pass through the module. The ground is supplied through the driver window switch as with normal operation. If the module continues to detect voltage on the down circuit for more than 480 ms after initial activation, the module will not affect operation. The down circuit through the module is a direct connection to the motor in its normal state. This allows the driver window switch to control the motor for normal operation. The passenger window motors are hardwired directly to the window regulator control switches. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch Power Window Switch: Testing and Inspection LR Window Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9507 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9508 Power Window Switch: Testing and Inspection Master Power Window Switch Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9509 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9510 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9511 Power Window Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9512 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9513 Power Window Switch: Testing and Inspection Right Rear Power Window Switch Component Testing Procedure Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 9514 Power Window Switch: Service and Repair REMOVAL 1. Remove the switch bezel. 2. Remove the screws. 3. Disconnect the connector. 4. Remove the master window regulator control switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions One Touch Window Down Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9520 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9521 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9522 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9523 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9524 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9525 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9526 One Touch Window Down Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9527 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9528 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9529 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following 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. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9530 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9531 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9532 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9533 One Touch Window Down Module: Connector Views Driver Door Module Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9534 Driver's Door Module (C520) Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9535 One Touch Window Down Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9536 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9537 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window Control Module] > Component Information > Diagrams > Page 9538 One Touch Window Down Module: Service and Repair REMOVAL CAUTION: Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 2. Remove the driver door trim panel. 3. Remove the Driver Door Module (DDM). 1 Disconnect the electrical connector. 2 Remove the screws. 3. Release the locking tab. INSTALLATION CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications > Electrical Specifications Power Window Motor: Electrical Specifications No Load Window Regulator Electric Drive Current Draw 5 A Or Less At 12.8 Volts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications > Electrical Specifications > Page 9543 Power Window Motor: Mechanical Specifications Window Regulator Electric Drive Screws 89 in.lb Window Regulator Motor to Regulator Screws 53 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor Power Window Motor: Service and Repair Rear Door Window Motor REMOVAL 1. Disconnect the battery ground cable. 2. Remove the rear door trim panel. 3. Remove the pull strap handle. 4. Remove the watershield. 5. Disconnect the connector. 6. Remove the rivets. NOTE: Use care not to enlarge the sheet metal holes in the door inner panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 9546 7. Remove the Torx (R) screws. NOTE: Working through the access hole, remove the window regulator motor bracket from the inner panel and slide the motor back to gain access to the screws. 8. Separate the window regulator motor from the window regulator and remove from the rear door. INSTALLATION 1. Install the Torx (R) screws. NOTE: Position the window regulator motor to the rear door electric window regulator and window regulator motor mounting bracket. 2. Install the rivets. NOTE: Position the window regulator motor mounting bracket to the inner panel. - 1/4-20 x 1/2 inch bolt and 1/4-20 nut and washer assemblies or equivalent metric fasteners may be used in place of the rivets. 3. Connect the connector. 4. Install the watershield. 5. Install the pull strap handle. 6. Install the rear door trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 9547 Power Window Motor: Service and Repair Front Door Window Motor REMOVAL 1. Remove the front door trim panel. 2. Position the front door window glass in the full up position and secure with tape. 3. Disconnect the battery ground cable. 4. Disconnect the connector. 5. Remove the rivets. 6. Remove the Torx (R) screws. NOTE: Working through the access hole, remove the motor bracket from the inner panel and slide the motor rear to the access hole in the door. 7. Separate the window regulator motor from the front door window regulator and remove it from the front door. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 9548 1. Install the screws. NOTE: Position the window regulator motor to the front door window regulator. 2. Install the three rivets. NOTE: Position the window regulator motor on the inner panel. 3. Connect the connector. 4. Connect the battery ground cable. 5. Remove the tape from the front window. 6. Check the front door window glass for correct operation. 7. Install the front door trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 9553 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 9554 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 9555 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 9556 Power Window Switch: Description and Operation PRINCIPLES OF OPERATION The driver power window one touch down operation is controlled by the Driver Door Module (DDM), if equipped with remote keyless entry, or the one touch down module if not equipped with remote keyless entry. The one touch down operation is requested of the module by momentarily pressing the driver window down switch for 32 ms to 480 ms. The module uses the initial voltage input from the down switch to begin one touch down operation. If the voltage input was less than 480 ms, the module will maintain the voltage supply to the motor down circuit. Circuit breaker 14 (20 A) supplies the power to the module for this operation. The module will maintain the operation until: seven seconds expire. - the module detects motor stalled by monitoring the current draw. - a voltage input is received by the module on either the up or down switch circuits. The ground for one touch down operation does not pass through the module. The ground is supplied through the driver window switch as with normal operation. If the module continues to detect voltage on the down circuit for more than 480 ms after initial activation, the module will not affect operation. The down circuit through the module is a direct connection to the motor in its normal state. This allows the driver window switch to control the motor for normal operation. The passenger window motors are hardwired directly to the window regulator control switches. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch Power Window Switch: Testing and Inspection LR Window Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9559 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9560 Power Window Switch: Testing and Inspection Master Power Window Switch Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9561 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9562 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9563 Power Window Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9564 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9565 Power Window Switch: Testing and Inspection Right Rear Power Window Switch Component Testing Procedure Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 9566 Power Window Switch: Service and Repair REMOVAL 1. Remove the switch bezel. 2. Remove the screws. 3. Disconnect the connector. 4. Remove the master window regulator control switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair Back Window Glass: Service and Repair REMOVAL WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the connectors, if equipped. 2. Remove the interior garnish mouldings. 3. Remove the rear window glass using a suitable suction tool. NOTE: Use a long knife to cut any remaining urethane stringers. 4. Trim the urethane on the pinch weld. NOTE: Clean around the pinch weld area to remove any dirt or foreign material that could contaminate the existing urethane once it is trimmed. 5. Inspect the pinch weld for damaged metal, rust or foreign objects. Repair the pinch weld as necessary. NOTE: To avoid rust formation, take extreme care not to scratch or otherwise damage the pinch weld. INSTALLATION 1. Apply urethane metal primer WSB-M2G234-C or equivalent to any exposed or damaged metal on the pinch weld. NOTE: A minimum of ten minutes is required for the primer surface to dry. 2. Place the rear window glass inside up on a low, stable work surface. NOTE: If a new rear window glass is to be installed, attach the new moulding to the edge of the glass starting at the top center, then working out, then down the pillars and around the corners. 3. Clean the rear window glass with a non-alcohol based window cleaner. 4. Apply the Urethane Glass Prep WSB-M5B280-C or equivalent to the rear window glass interior edges. - Apply the Urethane Glass Prep WSB-M5B280-C or equivalent to the rear window glass interior edges 21 mm (0.8 inch) wide along top and sides and 70 mm (2.75 inch) wide along the bottom. - Wipe the rear window glass where the Urethane Glass Prep WSB-M5B280-C or equivalent has been applied. - Repeat the application in Steps 1 and 2. NOTE: Wipe off the Urethane Glass Prep WSB-M5B280-C or equivalent immediately after application because it flash dries. Two coats of the Urethane Glass Prep WSB-M5B280-C or equivalent must be applied. - Use a clean wool applicator to apply the Urethane Glass Prep WSB-M5B280-C or equivalent. 5. Align the rear window glass to the body. - Place the rear window glass on the pinch weld. - Center the rear window glass in the opening. - Adjust the glass stops. - Mark the rear window glass alignment on the glass and the body with tape or a grease pencil. 6. Remove the rear window glass. 7. Apply the Urethane Glass Primer WSB-M2G314-A or equivalent to the interior edges of the rear window glass 21 mm (0.8 inch) wide along top and sides and 70 mm (2.75 inch) wide along the bottom. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 9571 NOTE: Urethane Glass Primer WSB-M2G314-A or equivalent must be mixed thoroughly for even pigmentation. - Urethane Glass Primer WSB-M2G314-A or equivalent must cure for a minimum of five minutes. 8. Apply an even bead of Urethane Adhesive WSB-M2G316-B or equivalent around the entire sheet metal flange on top of the existing bead of urethane. The bead should be approximately 8 mm (0.314 inch) at the base and 14 mm (0.55 inch) high and triangular in shape. NOTE: The rear window glass must be installed before the adhesive skins over. 9. Install the rear window glass on the pinch weld. Align the rear window glass to the body using the alignment marks. CAUTION: When replacing urethane-installed parts, do not drive the vehicle until the urethane has cured. At 21°C (70°F) and relative humidities above 50%, adequate cure time is typically 24 hours (less at higher temperature and higher humidities). See detailed instructions provided by the urethane manufacturer. Inadequate or incorrect curing can adversely affect the retention of the rear window glass. 10. Inspect the rear window glass for air or water leaks through the urethane. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Position the watershield out of the way. 1 Remove the speaker. 2 Disconnect the driver door module. 3 Position the watershield out of the way. 3. Remove the bolt. 4. Position the front door glass run front retainer forward. 5. Remove the rivets. CAUTION: Do not attempt to forcibly remove the rivets as damage to the front door window glass will result. NOTE: Before removing rivets, it is necessary to place a suitable block support between the front door window channel bracket and the door outer panel to help stabilize the front door window bracket during rivet removal. - Lower the front door window glass to gain access to the two front door window channel bracket rivets. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 9575 6. Remove the front door window glass. INSTALLATION 1. Position the front door window glass into the door frame. 2. Install two 1/4-inch rivets (use of 1/4-20 x 1 inch screw and washer assemblies and 1/4 inch-20 nut and washer are optional). Tighten the nut (if used) to 13 N.m (10 Lb-Ft). NOTE: Align the front door window glass with the front door window channel bracket, if necessary. 3. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the pull strap handle. 3. Remove the watershield. 4. Remove the interior weather strip. 5. Remove the rear door window glass. 6. Remove the rear door window garnish moulding. 7. Remove the exterior weatherstrip. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 9579 8. Remove the rear door top glass run and quarter window glass as an assembly. NOTE: Pull the quarter glass forward to loosen the rear door top glass run assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure to install the quarter window glass into the glass channel. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the pull strap handle. 3. Remove the watershield. 4. Remove the bolt. 5. Remove the rivets. CAUTION: Do not attempt to forcibly remove the rivets as damage to the rear door window glass may result prior to removing the rivet center pins, it is necessary to place a suitable block support between the door outer panel and the rear door window channel bracket to stabilize the rear door window glass during rivet removal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 9583 6. Remove the bolt. 7. Remove the rear door window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Position the watershield out of the way. 1 Remove the speaker. 2 Remove the driver door module. 3 Position the watershield out of the way. 3. Remove the front door window glass. 4. Disconnect the connector. 5. Remove the rivets. 6. Remove the Torx (R) screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 9588 7. Remove the nuts. 8. Remove the regulator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Upper Regulator Mounting Nuts 12 Nm Rear Door Window Regulator Motor Screws 6 Nm Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 9592 Rear Door Window Regulator: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the pull strap handle. 3. Remove the watershield. 4. Remove the rear door window glass. 5. Disconnect the connector. 6. Remove the rivets. 7. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 9593 8. Remove the rear door window regulator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Specifications Window Track: Specifications Door Glass Top Run Screws 9 ft.lb Front Door Glass Run Front Retainer Screw 9 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Specifications > Page 9597 Window Track: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior weatherstrip. 3. Remove the front door window glass. 4. Remove the interior gamish moulding. 5. Remove the bolt. 6. Remove the exterior weatherstrip. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Specifications > Page 9598 7. Remove the door glass top run. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: Customer Interest Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 9607 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: All Technical Service Bulletins Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 9613 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 9614 Windshield: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the windshield wiper pivot arms. WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the cowl top vent panel. 3. Remove the visors. 4. Remove the windshield garnish mouldings. 5. Remove the instrument panel upper finish panel. 6. Remove the interior rear view mirror. 7. Partially drop the headliner near the windshield opening and block with suitable material. 8. Using the special tool, cut the adhesive. Refer to manufacturer's instructions when using the tool. CAUTION: Cover the instrument panel in order to prevent possible damage. 9. Remove the windshield and moulding assembly using a suitable suction tool and place on a stable work surface. 10. Trim any remaining urethane on the pinch weld to within 1.0 and 2.0 mm (0.04 and 0.08 inch) thickness. NOTE: Clean the area around the existing urethane prior to trimming. 11. Check the pinch weld sealing area for damaged sheet metal, rust or foreign objects which may cause glass breakage. Repair the sheet metal if necessary. INSTALLATION 1. Apply Urethane Metal Primer ESB-M2G234-A or equivalent to any exposed or damaged metal on the pinch weld. NOTE: A minimum of ten minutes is required for the primer surface to dry. 2. Clean the windshield glass with a non-alcohol based window cleaner. 3. Using a wool applicator, wipe the interior glass edge with Urethane Glass Prep WSB-M5B280-C 21 mm (0.8 inch) wide along the top and sides and 70 mm (2.75 inch) wide along the bottom. Wipe off the glass prep and repeat the glass prep application. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 9615 NOTE: Wipe off the urethane glass prep WSB-M5B280-C or equivalent immediately after application because it flash dries. Two coats of the Urethane Glass Prep must be applied. 4. Align the windshield glass to the body. ^ Place the windshield glass to the body. ^ Center the windshield glass in the opening. ^ Adjust the windshield stops. ^ Mark the windshield glass alignment on the glass and the body. 5. Remove the windshield glass from the vehicle and place it back onto the work table. 6. Thoroughly shake and stir the Urethane Glass Primer WSH-M2G314-B or equivalent to make sure of even pigment mixing. 7. Using a clean wool applicator, apply primer to interior glass edges 21 mm (0.8 inch) along the top and sides and 70 mm (2.75 inch) wide along the bottom. NOTE: Allow a minimum of five minutes for the glass primer to dry. 8. Install the instrument panel upper finish panel. 9. Apply the new Urethane Adhesive WSB-M2G316-B or equivalent in an even bead onto the existing urethane on the pinch weld. NOTE: ^ Leave a door window slightly open until the adhesive is cured. ^ Apply the new urethane on top of the existing material on the pinch weld. ^ The newly-applied bead should be triangular in shape. 10. Install the windshield glass on the pinch weld, then align the windshield glass to the body using the alignment marks. 11. Install the cowl top vent panel. 12. Install the windshield pivot arms. 13. Install the headliner. 14. Install the visors. 15. Install the windshield garnish mouldings. 16. Install the interior rear view mirror. 17. Check the installation for air and water leaks through the urethane seal. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 9621 Wiper Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the tunnel brace trim cover. 1 Remove pin-type retainers. 2 Remove the tunnel brace trim cover. 3. Position the instrument panel ash receptacle aside. 1 Remove the screws. 2 Position the instrument panel ash receptacle aside. 4. Remove the instrument panel ash receptacle assembly. 1 Disconnect the electrical connector. 2 Remove the instrument panel ash receptacle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 9622 5. Remove the windshield wiper control module. 1 Remove the screw. 2 Disconnect the electrical connector. 3 Remove the windshield wiper control module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 9627 Windshield Washer Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 9628 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 9629 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 9630 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 9631 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 9635 Wiper Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 9636 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 9637 Wiper Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 9638 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 9639 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation The LOW WASHER FLUID warning indicator illuminates when windshield washer fluid level is below specified levels or a concern is detected in the windshield washer fluid level circuit. During prove-out, when a concern is detected or the windshield washer fluid level is low, an audible tone will sound and the LOW WASHER FLUID warning indicator will flash on and off for five seconds. The LOW WASHER FLUID warning indicator will then remain illuminated until the concern is corrected or the windshield washer fluid level is raised above specified level. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair REMOVAL 1. Remove the air cleaner assembly. 2. Position the pump and reservoir aside. 1 Remove the bolts. 2 Position the pump and reservoir aside. 3. Remove the washer pump and reservoir. 1 Disconnect the electrical connectors. 2 Disconnect the washer hose. 3 Remove the pump and reservoir. WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON LABEL OF WASHER SOLUTION CONTAINER. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hose is disconnected. 4. Remove the washer pump. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair REMOVAL 1. Remove the air cleaner assembly. 2. Position the pump and reservoir aside. 1 Remove the bolts. 2 Position the pump and reservoir aside. 3. Remove the washer pump and reservoir. 1 Disconnect the electrical connectors. 2 Disconnect the washer hose. 3 Remove the pump and reservoir. WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON LABEL OF WASHER SOLUTION CONTAINER. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hose is disconnected. 4. Remove the washer pump. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 9652 Windshield Washer Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 9653 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 9654 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 9655 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 9656 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications Wiper Arm: Specifications LH Wiper Pivot Arm Installation Position 2-26 mm RH Wiper Pivot Arm Installation Position 5-33 mm Mounting Arm and Pivot Shaft Bolts 106 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 9660 Wiper Arm: Adjustments NOTE: The windshield wiper pivot arm and windshield wiper blade assemblies are positioned using a key and keyway. If adjustment is required, use the following procedure: 1. Remove the wiper pivot arm. 2. Remove the key from the wiper pivot arm. 3. Cycle the wiper motor to the park position. 4. Install the LH wiper pivot arm to the specified position above the ramp stop. 5. Install the RH wiper pivot arm to the specified position above the ramp stop. 6. Lower the wiper pivot arms to the ramp stops. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 9661 Wiper Arm: Service and Repair REMOVAL 1. Remove the pivot arm. 1 Lift the pivot arm slightly off the glass. 2 Release the locking tab and rest the pivot arm on the locking tab. 3 Remove the pivot arm. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When installing the pivot arm on the pivot shaft, it is necessary to align the key on the pivot arm with the key on the pivot shaft. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments Wiper Blade: Adjustments NOTE: The windshield wiper pivot arm and windshield wiper blade assemblies are positioned using a key and keyway. If adjustment is required, use the following procedure: 1. Remove the wiper pivot arm. 2. Remove the key from the wiper pivot arm. 3. Cycle the wiper motor to the park position. 4. Install the LH wiper pivot arm to the specified position above the ramp stop. 5. Install the RH wiper pivot arm to the specified position above the ramp stop. 6. Lower the wiper pivot arms to the ramp stops. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 9668 Wiper Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the tunnel brace trim cover. 1 Remove pin-type retainers. 2 Remove the tunnel brace trim cover. 3. Position the instrument panel ash receptacle aside. 1 Remove the screws. 2 Position the instrument panel ash receptacle aside. 4. Remove the instrument panel ash receptacle assembly. 1 Disconnect the electrical connector. 2 Remove the instrument panel ash receptacle. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 9669 5. Remove the windshield wiper control module. 1 Remove the screw. 2 Disconnect the electrical connector. 3 Remove the windshield wiper control module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips Windshield Wiper Motor: Technical Service Bulletins Wipers/Washers - Wiper Motor Transfer Tips Article No. 03-7-2 04/14/03 ELECTRICAL - FRONT WIPER MOTOR - MOUNTING BRACKET AND DEPRESSED PARK OUT ARM - TRANSFER SERVICE TIPS FORD: 1987-1995 TAURUS 1987-2002 CROWN VICTORIA LINCOLN: 1987-1997 TOWN CAR 1988-1997 CONTINENTAL 1993-1998 MARK VIII MERCURY: 1987-1995 SABLE 1987-2002 GRAND MARQUIS Article 02-10-1 is being republished in its entirety to update the Service Procedure. ISSUE Motorcraft remanufactured front wiper motors do not include the mounting bracket or depressed park output arm. The mounting bracket and depressed park output arm must be transferred from the old wiper motor to the replacement wiper motor. Care must be taken to ensure proper orientation of the windlatch assembly and depressed park output arm. ACTION The front wiper motor mounting bracket and output arm must be removed from the old front wiper motor and installed on the remanufactured wiper motor if wiper motor replacement is required. Refer to the following service information for details. SERVICE PROCEDURE Disassembly: 1. Using a small flat bladed screwdriver, carefully remove the plastic output arm dust cover from the old wiper motor output arm to expose the output arm hold down bolt. NOTE THE DUST COVER WILL BE REINSTALLED DURING ASSEMBLY. 2. Remove the output arm attaching bolt. 3. Using a small light hammer, gently tap the backside of the output arm to remove the output arm from the wiper motor output shaft. Carefully observe the orientation of the plastic windlatch slide. NOTE TAKE CARE NOT TO DAMAGE THE PLASTIC WINDLATCH SLIDE OR BRACKET. IT IS NOT NECESSARY TO REMOVE THE PLASTIC WINDLATCH SLIDE OR METAL GUIDE FROM THE WIPER MOTOR MOUNTING BRACKET. 4. Remove the three (3) 8 mm wiper motor mounting bracket attaching bolts. 5. Remove the wiper motor bracket. Assembly: 1. Position and align the old wiper motor mounting bracket onto the new wiper motor. 2. Reinstall the three wiper motor mounting bracket bolts and torque to 108-156 Lb-in. (13-17 N.m). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9674 3. Verify that the plastic windlatch slide is positioned so that it can move an equal distance beyond both ends of the depressed park windlatch guide bracket. Make sure the tab on the windlatch is oriented in the proper direction for the specific application (Figure 1, views A and C). 4. Apply a thin film of Silicone Brake Caliper Grease (Motorcraft Part XG-3-A) to the mating surfaces of the plastic windlatch slide and the output arm. 5. Install the output arm onto the wiper motor output shaft according to the specific application (Figure 1, views B and D). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9675 NOTE THE OUTPUT SHAFT AND ARM ARE KEYED FOR PROPER ORIENTATION. 6. Reinstall the output arm bolt and torque to 132-180 Lb-in. (15-20 N.m). 7. Reinstall the plastic output arm dust cover. 8. Rotate the output arm slowly clockwise one full turn by hand, then turn the output arm by hand counter-clockwise to seat the detent in the output arm against the stop on the plastic windlatch slide. 9. Position the vehicle wiper arm linkage so that the wiper blades are at the bottom of the windshield, just above the parked position. 10. Install the wiper motor in the vehicle and connect the wiper arm linkage per the procedures outlined in Section 01-16 or Section 501-16 Wiper and Washer Systems - Removal and Installation, of the appropriate model year Workshop Manual. TROUBLESHOOTING: Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-10-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 290000 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component Information > Technical Service Bulletins > Page 9676 Windshield Wiper Motor: Specifications Windshield Wiper Motor Bolts 89 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component Information > Technical Service Bulletins > Page 9677 Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component Information > Technical Service Bulletins > Page 9678 Windshield Wiper Motor: Testing and Inspection CAUTION: Do not handle the windshield wiper motor abusively when diagnosing the wiper operations. Failure to do so may result in damage to the motor magnets and will make the windshield wiper motor inoperative. Rough handling of a new windshield wiper motor may also damage the motor magnets. Use Alternator, Regulator, and Starter Tester (ARBST) to test the wiper motor on the vehicle. To test the wiper motor, disconnect the wiper mounting arm and pivot shaft from the wiper motor. Disconnect the wiper motor connector. Connect the (A) green lead from the (B) ARBST to the positive post. Connect the (C) red lead from the tester to the wiper motor (D) common brush Pin 5 component side. Test the low speed mode by connecting a (E) cable from the battery negative post to the low speed brush Pin 6 and measure the current draw. If the current draw is greater than 3.5 amperes, install a new wiper motor. Test the high speed mode by connecting a cable from the battery negative post to the (G) high speed brush Pin 7 component side and measure the current draw. If the current draw is greater than 5.5 amperes, install a new wiper motor. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component Information > Technical Service Bulletins > Page 9679 Windshield Wiper Motor: Service and Repair REMOVAL 1. Remove the mounting arm and pivot shaft assembly. 2. Remove the windshield wiper motor cover. 3. Disconnect the wiper motor linkage. 1 Remove the clip. 2 Disconnect the linkage. 4. Remove the windshield wiper motor. 1 Remove the bolts. 2 Remove the motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips Wiper Motor Linkage: Technical Service Bulletins Wipers/Washers - Wiper Motor Transfer Tips Article No. 03-7-2 04/14/03 ELECTRICAL - FRONT WIPER MOTOR - MOUNTING BRACKET AND DEPRESSED PARK OUT ARM - TRANSFER SERVICE TIPS FORD: 1987-1995 TAURUS 1987-2002 CROWN VICTORIA LINCOLN: 1987-1997 TOWN CAR 1988-1997 CONTINENTAL 1993-1998 MARK VIII MERCURY: 1987-1995 SABLE 1987-2002 GRAND MARQUIS Article 02-10-1 is being republished in its entirety to update the Service Procedure. ISSUE Motorcraft remanufactured front wiper motors do not include the mounting bracket or depressed park output arm. The mounting bracket and depressed park output arm must be transferred from the old wiper motor to the replacement wiper motor. Care must be taken to ensure proper orientation of the windlatch assembly and depressed park output arm. ACTION The front wiper motor mounting bracket and output arm must be removed from the old front wiper motor and installed on the remanufactured wiper motor if wiper motor replacement is required. Refer to the following service information for details. SERVICE PROCEDURE Disassembly: 1. Using a small flat bladed screwdriver, carefully remove the plastic output arm dust cover from the old wiper motor output arm to expose the output arm hold down bolt. NOTE THE DUST COVER WILL BE REINSTALLED DURING ASSEMBLY. 2. Remove the output arm attaching bolt. 3. Using a small light hammer, gently tap the backside of the output arm to remove the output arm from the wiper motor output shaft. Carefully observe the orientation of the plastic windlatch slide. NOTE TAKE CARE NOT TO DAMAGE THE PLASTIC WINDLATCH SLIDE OR BRACKET. IT IS NOT NECESSARY TO REMOVE THE PLASTIC WINDLATCH SLIDE OR METAL GUIDE FROM THE WIPER MOTOR MOUNTING BRACKET. 4. Remove the three (3) 8 mm wiper motor mounting bracket attaching bolts. 5. Remove the wiper motor bracket. Assembly: 1. Position and align the old wiper motor mounting bracket onto the new wiper motor. 2. Reinstall the three wiper motor mounting bracket bolts and torque to 108-156 Lb-in. (13-17 N.m). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9684 3. Verify that the plastic windlatch slide is positioned so that it can move an equal distance beyond both ends of the depressed park windlatch guide bracket. Make sure the tab on the windlatch is oriented in the proper direction for the specific application (Figure 1, views A and C). 4. Apply a thin film of Silicone Brake Caliper Grease (Motorcraft Part XG-3-A) to the mating surfaces of the plastic windlatch slide and the output arm. 5. Install the output arm onto the wiper motor output shaft according to the specific application (Figure 1, views B and D). Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9685 NOTE THE OUTPUT SHAFT AND ARM ARE KEYED FOR PROPER ORIENTATION. 6. Reinstall the output arm bolt and torque to 132-180 Lb-in. (15-20 N.m). 7. Reinstall the plastic output arm dust cover. 8. Rotate the output arm slowly clockwise one full turn by hand, then turn the output arm by hand counter-clockwise to seat the detent in the output arm against the stop on the plastic windlatch slide. 9. Position the vehicle wiper arm linkage so that the wiper blades are at the bottom of the windshield, just above the parked position. 10. Install the wiper motor in the vehicle and connect the wiper arm linkage per the procedures outlined in Section 01-16 or Section 501-16 Wiper and Washer Systems - Removal and Installation, of the appropriate model year Workshop Manual. TROUBLESHOOTING: Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-10-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 290000 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Page 9686 Wiper Motor Linkage: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the cowl top vent panel. 3. Position the evaporative emission canister purge valve aside. 1 Remove the nuts. 2 Position the evaporative emission canister purge valve aside. 4. Position the mounting arm and pivot shaft aside. 1 Remove the bolts. 2 Position the mounting arm and pivot shaft aside. 5. Remove the mounting arm and pivot shaft. ^ Disconnect the electrical connector. ^ Disconnect the washer supply hose. NOTE: If necessary, remove the windshield wiper motor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Page 9687 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation The steering column switches consist of the following components: ^ The multifunction switch controls the following functions: turn signals - headlamp dimmer - headlamp flash-to-pass - hazard warnings-cornering lamps - windshield washer/wipers ^ Ignition switch Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 9691 Wiper Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 9692 Schematic NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at Ignition Switch / Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 9693 Wiper Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the shrouds. 5. Remove the multifunction switch. 1 Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 9694 2 Disconnect the electrical connectors. 3 Remove the switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy. To install, reverse the removal procedure.