Haynes Ford Escape & Mazda Tribute 2001 thru 2003 Automotive Repair Manual 1563925206, 9781563925207

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Ford Escape ¢@ Mazda Tribute 2001 thru 2003 o ati models

Haynes Repair Manual |

Based on a complete teardown and rebuild

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scape & azda ribute Automotive 629 28722 ST93F Stubblefield, Mike. Ford Escape & Mazda automotive

repair

Tribute manual

MID-CONTINENT PUBLIC LIBRARY North Independence Branch 317 W. Highway 24 Independence, MO 64050

Repair

Manual by Mike Stubblefield and John H Haynes Member of the Guild of Motoring Writers

Models covered:

Tins nan

Ford Escape and Mazda Tribute 2001 thru 2003

Mak 3 1 2021 LDL CONTINENT Dlintic tippany Mia CONTINENT PboLLG LIBRARY aioe TOMCTINIE x Cescores C MEMBER

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA

Acknowledgements Wiring diagrams originated exclusively for Haynes North America, Inc. by Valley Forge Technical Information Services. Technical writers who contributed to this project include Rob Maddox and John Wegmann.

© Haynes North America, Inc. 2003 With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Automotive Repair Manual Series Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 56392 520 6 Library of Congress Control Number 2003112702 While every attempt is made to ensure that the information in this. manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given. 03-320

MID-CONTINENT PUBLIC LIB

MID-CONTINENT PUBLIC LIBRARY

North Independence Branch

317 W. Highway 24 Independence, MO 64050

by be

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Contents Introductory pages About this manual Introduction to the Ford Escape and Mazda Tribute Vehicle identification numbers Buying parts Maintenance techniques, tools and working facilities Jacking and towing Booster battery (jump) starting Fraction/decimal/millimeter equivalents Conversion factors Safety first! Automotive chemicals and lubricants Troubleshooting

0-5 0-5 0-6 0-6 0-7 0-13 0-14 0-15 0-16 0-17 0-18 0-19

Chapter 1 Tune-up and routine maintenance

Chapter 2

Part A.

Four-cylinder engine

Chapter 2

PartB

V6 engine

Chapter 2

PartC

General engine overhaul procedures

Chapter 3 Cooling, heating and air conditioning systems

Chapter 4

‘

Fuel and exhaust systems

4-1

Chapter 5

:

Engine electrical systems

5-1

Chapter 6

:

Emissions and engine control systems Chapter 7

PartA

Manual transaxle

Chapter 7

TA-1

PartB

Automatic transaxle

Chapter 7

6-1

7B-1

Part C

Transfer case

7C-1

Chapter 8 Clutch and driveline

8-1

Chapter 9 Brakes

9-1

Chapter 10 Suspension and steering systems

10° 10-1

oo

Chapter 11 Body

11-1

Chapter 12 Chassis electrical system

=

11 12 .

12-1.

Wiring diagrams

12-25

Index

iIND-1

IND

:

Haynes mechanic, author and photographer with a 2002 Ford Escape

.

0-5

About this manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble

occurs. : We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop

must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within

that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word “Chapter” apply to Sections and/or paragraphs in the same Chapter. For example, “see Section 8” means in the same Chapter. References to the left or right side of the

vehicle assume you are sitting in the driver’s seat, facing forward. Even though we have prepared this manual with extreme care, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

CAUTION '

A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.

WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury.

Introduction to the Ford Escape and Mazda Tribute This manual covers the Ford Escape and Mazda Tribute. The available engines are: The 2.0L Zetec in-line four-cylinder engine and the 3.0L Duratec V6 engine. The engine drives the front wheels through either a five-speed manual or a fourspeed automatic transaxle via independent

driveaxles. On 4WD models the rear wheels are also propelled, via a driveshaft, rear differential, and two rear driveaxles. Suspension is independent at all four wheels, MacPherson struts being used at the front end and trailing arms, control arms, coil springs and telescopic shock absorbers at

the rear. The rack-and-pinion steering unit is mounted on the suspension crossmember. The brakes are disc,at the front and drums at the rear, with power assist standard. Some models are equipped with an

optional Anti-lock Brake System (ABS).

Vehicle identification numbers Modifications are a continuing and unpublicized process in vehicle manufacturing. Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are essential to correctly identify the component required.

lation label is attached to the driver’s side door end or post (see illustration). The label contains the name of the manufacturer, the month and year of production, the Gross Vehicle Weight Rating (GVWR), the Gross

On V6 models, the engine identification number is stamped into a machined pad on

the right end (driver’s side) of the engine block (see illustration).

Axle Weight Rating (GAWR) and the certification statement.

Vehicle Identification Number

(VIN) This very important identification number is stamped on a plate attached to the dashboard inside the windshield on the driver’s side of the vehicle (see illustration). The VIN also appears on the Vehicle Certificate of Title and Registration. It contains information such as where and when the vehicle was manufactured, the model year and the body style.

Manufacturer’s Certification Regulation label The Manufacturer’s Certification Regu-

VIN model year code Counting from the left, the model year code letter designation is the 10th character. On all models covered by this manual the model year codes are:

oxvarthusassteveseecosureecrs ceesoass CUS Se A rE Aan cteT ae Oana r erence sabcmne san cc Sessa

2001 2002 2003

Engine number On four-cylinder

models,

the engine

identification number is stamped into a machined pad on the front-side of the engine. under the exhaust manifold.

Location of the Manufacturer’s Certification Regulation label

The Vehicle Identification Number (VIN) is visible through the driver’s side of the windshield :

Location of the engine identification number - V6 engine

Buying parts Replacement parts are available from many sources, which generally fall into one of two categories - authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these parts is as follows: Retail auto parts stores; Good auto parts stores will stock frequently needed components which wear out relatively fast, such as clutch components, exhaust sys-

parts on an exchange basis, which can save a considerable amount of money. Discount auto parts stores are often very good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and

tems, brake parts, tune-up parts, etc. These

Authorized dealer parts department: This is the best source for parts which are

stores often supply new

or reconditioned

general accessories, have convenient.hours, charge lower prices and can often be found

not far from home.

unique to the vehicle and not generally available elsewhere (such as major engine parts, transmission parts, trim pieces, etc.). Warranty information: lf the vehicle is still covered under warranty, be sure that any replacement parts purchased - regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine ‘and chassis numbers available and, if possible, take the old parts along for positive identification.

vo

_ Maintenance techniques, tools and working facilities Maintenance techniques There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the

Most automotive machine shops can perform this task, as well as other repair procedures, such as the repair of threaded holes that have been stripped out. Flat washers and lockwashers, when

removed from an assembly, should always be replaced exactly as removed. Replace any damaged washers with new ones. Never use a lockwasher on any soft metal surface (such as aluminum), thin sheet metal or plastic.

repair job is thorough and complete.

Fasteners Fasteners are nuts, bolts, studs and screws used to hold two or more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type, - either a lockwasher, locknut, locking tab or thread adhesive. All threaded fasteners should be clean and straight, with undamaged threads and undamaged corners on the hex head where the wrench fits. Develop the habit of replacing all damaged nuts and bolts with new ones. Special locknuts with nylon or fiber inserts can only be used once. If they are removed, they lose their locking ability and must be replaced with new ones. Rusted nuts anc bolts should be treated with a penetrating fiuid to ease removal and prevent breakage. Some mechanics use turpentine in a spout-type oil can, which works quite well. After applying the rust penetrant, let it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have to be chiseled or sawed off or removed with a special nut breaker, available at tool stores.

If a bolt or stud breaks off in an assembly, it can be drilled and removed with a special tool commonly available for this purpose.

x Grade 1 or 2

Grade 5

Grade 8

gh Bolt strength marking (standard/SAE/USS; bottom - metric)

Grade Hex Nut

=

identification i.

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Grade

Identification

Hex Nut

‘Clase8

3 Dots

ne

6»

cy 6 Dots

Standard hex nut strength markings

sou Arabic 10

Metric hex nut strength markings

Metric stud strength markings 00-1 HAYNES

0-8

Maintenance techniques, tools and working facilities aE

2

Fastener sizes For a number of reasons, automobile manufacturers are making wider and wider use of metric fasteners. Therefore, it is important to be able to tell the difference between standard (sometimes called U.S. or SAE) and metric hardware, since they cannot be interchanged. All bolts, whether standard or metric, are sized according to diameter, thread pitch and length. For example, a standard 1/2 - 13 x 1 bolt is 1/2 inch in diameter, has 13 threads per inch and is 1 inch long. An M12 1.75 x 25 metric bolt is 12 mm in diameter, has a thread pitch of 1.75 mm (the distance between threads) and is 25 mm long. The two bolts are nearly identical, and easily confused, but they are not interchangeable. In addition to the differences in diameter, thread pitch and length, metric and standard bolts can also be distinguished by examining the bolt heads. To begin with, the ~ distance across the flats on a standard bolt head is measured in inches, while the same

Metric thread sizes

V/Bese y arces sted

cohetene time epttre a erureets tees

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ee Bade A eae eae Ge sey oes

Ft-lbs 6 to 9 14 to 21 28 to 40 50 to 71 80 to 140

Nm 9 to 12 19 to 28 38 to 54 68 to 96 109 to 154

5 to8 12 to 18 22 to 33 25 to 35

7 to 10 17 to 24 30 to 44 34 to 47

6 to9 12to 14 to 22 to 27 to 40 to 40 to 55 to

9 to 12 17 to 24 19 to 27 30 to 43 Sh toil 55 to 74 55 to 81 75 to 108

18 20 32 38 55 60 80

-

dimension on a metric bolt is sized in millimeters (the same is true for nuts). As a result, a standard wrench should not be used on a metric bolt and a metric wrench should not be used on a standard bolt. Also, most standard bolts have slashes radiating out from the center of the head to denote the grade or

T—>||

Make the booster battery cable connections in the numerical order shown (note that the negative cable of the booster battery is NOT attached to the negative terminal of the dead battery)

0-15 DECIMALS to MILLIMETERS Decimal

FRACTIONS to DECIMALS to MILLIMETERS Fraction

| Decimal

mm

‘| Fraction

| Decimal

' mm

0.0254 0.0508

12.7000 12.9540

1/64 1/32

0.0156 0.0312

0.3969 0.7938

33/64 17/32

0.5156 0.5312

13.0969 13.4938

0.0762 0.1016 0.1270 0.1524 0.1778 0.2032 0.2286 0.2540

13.2080 13.4620 13.7160 13.9700 14.2240 14.4780 14.7320 14.9860

3/64

0.0469

1.1906

35/64

0.5469

13.8906

1/16

0.0625

1.5875

9/16

0.5625

14.2875

5/64 3/32 7/64

0.0781 0.0938 0.1094

1.9844 2.3812 2.7781

37/64 19/32 39/64

0.5781 0.5938 0.6094

14.6844 15.0812 15.4781

0.5080 0.7620 1.0160 1.2700 1.5240 1.7780 2.0320 2.2860

|

15.2400 15.4940 15.7480 16.0020 16.2560 16.5100 16.7640 17.0180 17.2720 17.5260

1/8

0.1250

3.1750

5/8

0.6250

15.8750

5/32

0.1406 0.1562 0.1719

3.5719 3.9688 4.3656

41/64 21/32 43/64

0.6406 0.6562 0.6719

16.2719 16.6688 17.0656

0.1875

4.7625

11/16

0.6875

17.4625

4.0640

17.7800

32,

4.3180 4.5720 4.8260

18.0340 18.2880 18.5420 18.7960

0.2031 0.2188 0.2344

5.1594 5.5562 5.9531

45/64 23/32 47/64

0.7031 0.7188 0.7344

17.8594 18.2562 18.6531

0.2500

6.3500

3/4

0.7500

19.0500

5.0800

19.0500

9/32

0.2656 0.2812 0.2969

6.7469 7.1438 7.5406

49/64 25/32 51/64

0.7656 0.7812 0.7969

19.4469 19.8438 20.2406

5/16

0.3125

7.9375

13/16

0.8125

| 20.6375

11/32

0.3281 0.3438

8.3344 8.7312

53/64 27/32

0.8281 0.8438

| 21.0344 | 21.4312

0.3594

9.1281

55/64

0.8594

21.8281

0.3750

9.5250

7/8

0.8750

22.2250

0.3906 0.4062 0.4219

9.9219 10.3188 10.7156

57/64 29/32 59/64

0.8906 0.9062 0.9219

22.6219 23.0188 23.4156

0.4375

11.1125

15/16

0.9375

23.8125

15/32

0.4531 0.4688 0.4844

11.5094 11.9062 12.3031

31/32

0.9531 0.9688 0.9844

24.2094 24.6062 25.0031

1/2

0.5000

12.7000

I

1.0000

25.4000

2.5400 2.7940 3.0480 3.3020 3.5560

‘|

3.8100

5.3340

19.3040

5.5880 5.8420

19.5580 19.8120

6.0960 6.3500 6.6040

20.0660

20.3200

6.8580 7.1120 ee 7.6200

70.5740 21.8280 21.0820 71.3360

7.8740 8.1280 8.3820 8.6360 8.8900 9.1440 9.3980 9.6520 9.9060

21.5900 21.8440 22.0980 22.3520 22.6060

10.1600 10.4140 10.6680 10.9220 11.1760 11.4300 11.6840 11.9380 12.1920 12.4460

13/32

|

|

|

0-16

Conversion

factors

Length (distance)

=Inches (in) =Feet (ft) =Miles

=Millimeters (mm) =Meters (m) = Kilometers (km)

X X xX

0.0394 3.281 0.621

Cubic inches (cu in; in*) Imperial pints (Imp pt) Imperial quarts (Imp qt)

X 16.387 = Cubic centimeters (cc; cm’) X 0.568 = Liters (I) X 1.137 = Liters (I)

X x 4

0.061 1.76 0.88

=Cubic inches (cu in; in°) = Imperial pints (Imp pt) = Imperial quarts (Imp qt)

Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)

X

1.201

X X X X

0.946 4.546 1.201 3.785

X X x X X

0.833 1.057 0.22 0.833. 0.264

=Imperial quarts (Imp qt) =US quarts (US qt) = Imperial gallons (Imp gal) =Imperial gallons (Imp gal) =US gallons (US gal)

X X

28.35 0.454

=Grams (g) = Kilograms (kg)

X X

0.035 2.205

=Ounces (oz) = Pounds (Ib)

X X X

0.278 4.448 0.1.

=Newtons (N) =Newtons (N) =Kilograms-force (kgf; kg)

x X x

3.6 0.225 9.81

= Ounces-force (ozf; oz) =Pounds-force (Ibf; Ib) = Newtons (N)

X

0.070

= Kilograms-force per square

X

14.223

= Pounds-force per square inch

xX

14.696

= Pounds-force per square inch

X X X

Inches (in) Feet (ft) Miles

25.4 0.305 1.609

Volume (capacity)

:

=US quarts (US qt) = Liters (I) = Liters (I) =US gallons (US gal) = Liters (I)

Mass (weight) Ounces (oz) Pounds (Ib)

Force Ounces-force (ozf; oz) Pounds-force (Ibf; Ib) Newtons (N)

Pressure Pounds-force per square inch

(psi; Ibf/in?; Ib/in?)

centimeter (kgf/cm?; kg/cm?)

Pounds-force per square inch

(psi; Ibf/in?; Ib/in?)

X

0.068

=Atmospheres

per square inch

xX

0.069

=Bars

x

14.5

= Pounds-force per square inch

Pounds-force per square inch

X

6.895

= Kilopascals (kPa)

X

0.145

= Pounds-force per square inch

Kilopascals (kPa)

X

0.01

= Kilograms-force per square

x

98.1

X

1.152

X

0.868

X

0.113

= Kilograms-force centimeter (kgf cm; kg cm) =Newton meters (Nm)

x

8.85

Pounds-force inches

X

0.083

= Pounds-force feet (Ibf ft; Ib ft)

X

12

(Ibf in; Ib in) Pounds-force feet (Ibf ft; Ib ft)

X

0.138

= Kilograms-force meters

X

7.233

= Pounds-force feet (Ibf ft; Ib ft)

Pounds-force feet (Ibf ft; Ib ft) Newton meters (Nm)

X X

1.356 0.102

=Newton meters (Nm) = Kilograms-force meters (kgf m; kg m)

X xX

0.738 9.804

=Pounds-force feet (Ibf ft; Ib ft) =Newton meters (Nm)

X X

3.377 25.4

= Kilopascals (kPa) =Millimeters mercury (mm Hg)

X X

0.2961 0.0394

= Inches mercury

X 745.7

=Watts (W)

X

0.0013

= Horsepower (hp)

X

1.609

= Kilometers per hour (km/hr; kph) X

0.621

= Miles per hour (miles/hr; mph)

X X

0.354 0.425

= Kilometers per liter (km/I) = Kilometers per liter (km/I)

2.825 2.352

=Miles per gallon, Imperial (mpg) =Milles per gallon, US (mpg)

(atm)

(psi; Ibf/in?; Ib/in?)

(psi; Ibf/in?; Ib/in?) Pounds-force

(psi; Ibf/in?; Ib/in?) (psi; Ibf/in?; Ib/in?)

centimeter (kgf/cm?; kg/cm?)

(psi; Ibf/in?; Ib/in?)

(psi; Ibf/in?; Ib/in?)

= Kilopascals (kPa)

Torque (moment of force) Pounds-force inches (Ibf in; Ib in) Pounds-force inches

= Pounds-force inches (Ibf in; Ib in) = Pounds-force inches,

(Ibf in; Ib in)

(Ibf in; Ib in) = Pounds-force inches

(Ibf in; Ib in)

(kgf m; kg m)

Vacuum Inches mercury (in. Hg) Inches mercury (in. Hg)

= Inches mercury

Power

Horsepower (hp) Velocity (speed) Miles per hour (miles/hr; mph)

Fuel consumption* Miles per gallon, Imperial (mpg) Miles per gallon, US (mpg)

Temperature Degrees Fahrenheit

= (°C x 1.8) + 32

X X

Degrees Celsits (Degrees Centigrade; °C)

*/t is common practice to convert from miles per gallon (mpg) to liters/100 kilometers (i/100km), where mpg (Imperial) x I/100 km = 282 and mpg (US) x 1/100 km = 235

= (°F - 32) x 0.56

0-17

Safety first! Regardless of how enthusiastic you may be about getting on with the job at

hand, take the time to ensure that your safety is not jeopardized. A moment’s lack of attention can result in an accident, as can failure to observe certain simple safety precautions. The possibility of an accident will always exist, and the following points should not be considered a comprehensive list of all

dangers. Rather, they are intended to make you aware of the risks and to encourage a safety conscious approach to all work you carry out on your vehicle.

Essential DOs and DON’Ts DON’T rely on a jack when working under the vehicle. Always use approved jackstands to support the weight of the vehicle and place them under the recommended lift or support points. DON’T attempt to loosen extremely tight fasteners (i.e. wheel lug nuts) while the vehicle is on ajack - it may fall. DON’T start the engine without first making sure that the transmission is in Neutral (or Park where applicable) and the parking brake is set. DON’T remove the radiator cap from a hot cooling system - let it cool or cover it with a cloth and release the pressure gradually. DON’T attempt to drain the engine oil until you are sure it has cooled to the point that it will not burn you. DON’T touch any part of the engine or exhaust system until it has cooled sufficiently to avoid burns. DON’T siphon toxic liquids such as gasoline, antifreeze and brake fluid by mouth, or allow them to remain on your skin. DON’T inhale brake lining dust - it is potentially hazardous (see Asbestos below). DON’T allow spilled oil or grease to remain on the floor - wipe it up before someone slips

5 on it. DON’T use loose fitting wrenches or other tools which may slip and cause injury. DON’T push on wrenches when loosening or tightening nuts or bolts. Always try to pull the wrench toward you. If the situation calls for pushing the wrench away, push with an open hand to avoid scraped knuckles if the wrench should slip. DON’T attempt to lift a heavy component alone - get someone to help you. DON’T rush or take unsafe shortcuts to finish a job. DON’T allow children or animals in or around the vehicle while you are working on it. DO wear eye protection when using power

tools such as a drill, sander, bench grinder, etc. and when working under a vehicle. DO keep loose clothing and long hair well out of the way of moving parts. DO make sure'that any hoist used has a safe working load rating adequate for the job. DO get someone to check on you periodically when working alone on a vehicle. DO carry out work in a logical sequence and make sure that everything is correctly assembled and tightened. DO keep chemicals and fluids tightly capped and out of the reach of children and pets. DO remember that your vehicle’s safety affects that of yourself and others. If in doubt on any point, get professional advice.

Asbestos Certain friction, insulating, sealing, and other products - such as brake linings, brake bands, clutch linings, torque converters, gaskets, etc. - may contain asbestos. Extreme care must be taken to avoid inhalation of dust from such products, since it is hazardous to

health. If in doubt, assume that they do contain asbestos.

Fire Remember at all times that gasoline is highly flammable. Never smoke or have any kind of open flame around when working on a vehicle. But the risk does not end there. A spark caused by an electrical short circuit, by two metal surfaces contacting each other, or even by static electricity built up in your body under certain conditions, can ignite gasoline

vapors, which in a confined space are highly explosive. Do not, under any circumstances, use gasoline for cleaning parts. Use an approved safety solvent. Always disconnect the battery ground (-) cable at the battery before working on any part of the fuel system or electrical system. Never risk spilling fuel on a hot engine or exhaust component. It is strongly recommended that a fire extinguisher suitable for use on fuel and electrical fires be kept handy in the garage or workshop at all times. Never try to extinguish a fuel or electrical fire with water.

The battery Never create a spark or allow a bare light bulb near a battery. They normally give off a certain amount of hydrogen gas, which is highly explosive. Always disconnect the battery ground (-) cable at the battery before working on the fuel or electrical systems. If possible, loosen the filler caps or cover when charging the battery from an external source (this does not apply to sealed or maintenance-free batteries). Do not charge at an excessive rate or the battery may burst. Take care when adding water to a non maintenance-free battery and when carrying a battery. The electrolyte, even when diluted, is very corrosive and should not be allowed to contact clothing or skin. Always wear eye protection when cleaning the battery to prevent the caustic deposits from entering your eyes.

Household current When using an electric power tool, inspection light, etc., which operates on household current, always make sure that the tool is correctly connected to its plug and that, where necessary, it is properly grounded. Do not use such items in damp conditions and, again, do not create a spark or apply excessive heat in the vicinity of fuel or fuel vapor.

Secondary ignition system voltage

Fumes Certain fumes are highly toxic and can quickly cause unconsciousness and even death if inhaled to any extent. Gasoline vapor falls into this category, as do the vapors from some cleaning solvents. Any draining or

pouring of such volatile fluids should be done in a well ventilated area. When using cleaning

vents, read the instructions on the container carefully. Never use materials from unmarked containers. Never run the engine in an enclosed space, such as a garage. Exhaust fumes contain carbon monoxide, which is extremely poisonous. If you need to run the engine, always do so in the open air, or at least have the rear of the vehicle outside the work area. If you are fortunate enough to have the use of an inspection pit, never drain or pour gasoline and never run the engine while the vehicle is over the pit. The fumes, being heavier than air, will concentrate in the pit with possibly lethal results.

fluids and

sol-

A severe electric shock can result from touching certain parts of the ignition system (such as the spark plug wires) when the engine is running or being cranked, particularly if components are damp or the insulation is defective. In the case of an electronic ignition system, the secondary system voltage is

much higher and could prove fatal.

0-18

Automotive chemicals and lubricants A number of automotive chemicals and lubricants are available for use during vehicle maintenance and repair. They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber, plastic and vinyl.

Cleaners Carburetor cleaner and choke cleaner is a strong solvent for gum, varnish and carbon. Most carburetor cleaners leave a drytype lubricant film which will not harden or gum up. Because of this film it is not recommended for use on electrical components. Brake system cleaner is used to remove brake dust, grease and brake fluid from the brake system, where clean surfaces are absolutely necessary. It leaves no residue and often eliminates brake squeal caused by contaminants. Electrical cleaner removes oxidation, corrosion and carbon deposits from electrical contacts, restoring full current flow. It can also be used to clean spark plugs, carburetor jets, voltage regulators and other parts where an oil-free surface is desired. Demoisturants remove water and moisture from electrical components such as alternators, voltage regulators, electrical connectors and fuse blocks. They are non-conductive and non-corrosive. Degreasers are heavy-duty solvents used to remove grease from the outside of the engine and from chassis components. They can be sprayed or brushed on and, depending on the type, are rinsed off either with water or solvent.

Lubricants Motor oil is the lubricant formulated for use in engines. It normally contains a wide variety of additives to prevent corrosion and

reduce foaming and wear. Motor oil comes in various weights (viscosity ratings) from 0 to 50. The recommended weight of the oil depends on the season, temperature and the demands on the engine. Light oil is used in cold climates and under light load conditions. Heavy oil is used in hot climates and where high loads are encountered. Multi-viscosity oils are designed to have characteristics of both light and heavy oils and are available in a number of weights from 5W-20 to 20W-50. Gear oil is designed to be used in differentials, manual transmissions and other areas where high-temperature lubrication is required. Chassis and wheel bearing grease is a heavy grease used where increased loads and friction are encountered, such as for wheel bearings, balljoints, tie-rod ends and universal joints. High-temperature wheel bearing grease is designed to withstand the extreme

temperatures encountered by wheel bearings in disc brake equipped vehicles. It usually contains molybdenum disulfide (moly), which is a dry-type lubricant. White grease is a heavy grease for metal-to-metal applications where water is a

problem. White grease stays soft under both low and high temperatures (usually from -100 to +190-degrees F), and will not wash off or dilute in the presence of water. Assembly lube is a special extreme pressure lubricant, usually containing moly, used to lubricate high-load parts (such as main and rod bearings and cam lobes) for initial start-up of a new engine. The assembly lube lubricates the parts without being squeezed out or washed away until the engine oiling system begins to function. Silicone lubricants are used to protect rubber, plastic, vinyl and nylon parts. Graphite lubricants are used where oils cannot be used due to contamination problems, such as in locks. The dry graphite will lubricate metal parts while remaining uncontaminated by dirt, water, oil or acids. It is elec-

trically conductive and will not foul electrical contacts in locks such as the ignition switch. Moly penetrants loosen and lubricate frozen, rusted and corroded fasteners and prevent future rusting or freezing. Heat-sink grease is a special electrically non-conductive grease that is used for mounting electronic ignition modules where it is essential that heat is transferred away from the module.

Sealants RTV sealant is one of the most widely used gasket compounds. Made from silicone, RTV is air curing, it seals, bonds, waterproofs, fills surface irregularities, remains flexible, doesn’t shrink, is relatively easy to remove, and is used as a supplemen-

tary sealer with almost all low and medium temperature gaskets. Anaerobic sealant is much like RTV in that it can be used either to seal gaskets or to form gaskets by itself. It remains flexible, is solvent resistant and fills surface imperfections. The difference between an anaerobic sealant and an RTV-type sealant is in the curing. RTV cures when exposed to air, while an anaerobic sealant cures only in the absence of air. This means that an anaerobic sealant cures only after the assembly of parts, sealing them together. Thread and pipe sealant is used for

sealing hydraulic and pneumatic fittings and vacuum lines. It is usually made from a Teflon compound, and comes in a spray, a paint-on liquid and as a wrap-around tape.

Chemicals Anti-seize compound prevents seizing,

galling, cold welding, rust and corrosion in fasteners. High-temperature ant-seize, usually made with copper and graphite lubricants, is used for exhaust system and exhaust manifold bolts. Anaerobic locking compounds are used to keep fasteners from vibrating or working loose and cure only after installation, in the absence of air. Medium strength locking compound is used for small nuts, bolts and screws that may be removed later. Highstrength locking compound is for large nuts, bolts and studs which aren’t removed on a regular basis. Oil additives range from viscosity index improvers to chemical treatments that claim to reduce internal engine friction. It should be noted that most oil manufacturers caution against using additives with their oils. Gas additives perform several functions, depending on their chemical makeup. They usually contain solvents that help dissolve gum and varnish that build up on carburetor, fuel injection and intake parts. They also serve to break down carbon deposits that form on the inside surfaces of the combustion chambers. Some additives contain upper cylinder lubricants for valves and piston rings, and others contain chemicals to

remove condensation from the gas tank.

Miscellaneous Brake fluid is specially formulated hydraulic fluid that can withstand the heat and pressure encountered in brake systems. Care must be taken so this fluid does not come in contact with painted surfaces or plastics. An opened container should always

be resealed to prevent contamination by water or dirt. Weatherstrip adhesive is used to bond weatherstripping around doors, windows and trunk lids. It is sometimes used to attach trim pieces. Undercoating is a petroleum-based, tar-like substance that is designed to protect metal surfaces on the underside of the vehicle from corrosion. It also acts as a sounddeadening agent by insulating the bottom of the vehicle. Waxes and polishes are used to help protect painted and plated surfaces from the weather. Different types of paint may require the use of different types of wax and polish. Some polishes utilize a chemical or abrasive cleaner to help remove the top layer of oxidized (dull) paint on older vehicles. In recent years many non-wax polishes that contain a wide variety of chemicals such as polymers and silicones have been introduced. These non-wax polishes are Usually easier to apply and last longer than conventional waxes and ‘polishes.

0-19

Troubleshooting Contents

Section

Symptom

| Symptom

Section

Noise most Pronounced WheN turning ........ccceccescceccesccsesescesscesseese

42

Engine will not rotate when attempting to start .occcccc.cccccssssssseesesee Engine rotates but will not Start cccccccccccccccsccsscecsseceseececeeeeeeceeeecceece. Engine hard to start WHEN COI ooecceccccssessccssccssesseecceeeseeseeeeceeseeeseecs,

; 9 3

Clunk on acceleration or deceleration ........-secsssecrsecssseeessecsssee Clicking MOIS OMIAPEUI Se eeeeseettase ye etet eran nee erect ees eee eee eee Vibration Monee soeeennee soeeenneennee seetneeeaeenneenncenneeesecnnccnssasenteceneetneas

43 44 45

SIND VANE TOCST APE WIEN OL SS cnsc enclaves alecvenndcescshdceneana@ions Starter motor noisy or excessively rough in engagement.............. Engine starts but stops immediately .......cccssssecssssssssssscsssssssssssceeeee

4 5 6

Nols yal netiee Withy ODGINS TURING aaa teeere s aa Noisy in one PaNticUlan QCal eran ene mer eet neers NOISY iM All GOALS... eesssessssessserseeesseessseesssesssessuensncensecessensnecntcees

se 47 48

7

aaecaaeec geneedoatect vee Mirae aoe Slips out of GOAN sc cedssecs sdhplakevetseneces

Engine

Oil puddle under engine .......--.......-. LE

EY 08S. 8

ee AE

Engine lopes while idling or idles erratically... scence cnn, 6. ecisedecsscsacec Menaine misses at idle speed...

8 9

ee Leaks lubricant Lins titesala abagashesvesguaitenauei eco Sensi be sen Sace ea ee Ue Locked in JOAN aes erinversnnetntns hss deste Bynocth acy s koh a apseeee kee eeer aie pete

49

50 51

Engine misses throughout driving speed range..........cccccescesceeeeeees

10

Automatic transaxle

Engine stumbles on acceleration ............:.0.-css-scsccsassceseseeversoesoeseee Engine surges while holding accelerator steady 20...

11 42

; Fluid leakage ns eee spe seed io Ochs

EMG CastellStee vere secvssceae Mere tree eae Nace ots sss feoundasedasciostanedennss

13

ee

EAginellaCKS POW Clie trace retreats reasaiceaas novasiiaesateets cad easels BEING NDACI Sreractencuevece ste eit tecc etrey tru.nstaacadcteneeriadateatnenteens Pinging or knocking engine sounds during acceleration

14 fey

General shift inechanisns PFODIGMS «-ssosssssssssssseereseseeneettinesssstenccone Transaxle slips, shifts roughly, is noisy or has no drive in renee encase ee seen nce ssoocoees forward /'Orreverse :GeaMsicc.ssc-ccsm

55

E | eetssae t-seeeactsaanc cosets cea 5 Maes ac santas Cones cule mceaes tek eee CPU Engine runs with oil pressure light ON ..........ccccccccessesesssceeesseeeeeeesees

16 AWW?

Driveaxles Cliskiamolse tn tunie

56

ees

oo

ees torun) aller Switching Offs reese

Engine electrical systems

ie

Z

Battery WillmOtMmOld a Chale. aist-2sc.--csverar’scensesoc-ccepeupapvevcevsvesecesers ALOrnatOriliGhe tallS £0; QO) OUts -i-..c.--hcces0s2-ceseesd9cce0cnyaseeeucuseeMeaetee

Alternator light fails to come on when key is turned OM.....sessseeee-

19 20

24

Fuel system

EXC RIVE ALO! CONSUIMPUION o5cc.scccc--asntaneraotesv ished esovieet lavovevesaene

Fltel leakage and/or fle! O08 .....c.cscc-.sscsscessascesoasessssesscsnsonsucracteres

e

Randa at endeared eines aan YR eee eae

st Donor Rie BUIREC STG ase osde

cece eee

52

aeci

oS

a

Shudder or vibration during acceleration ............ccccccccesssssceeeeesseees Vibrationsat highWay SPCCGS 4 sss

tenvereeessnees teresa

Brakes

f

:

:

54

57 58

Vehicle pulls to one side during braking .......--s sesvnneeeneseeneaes

59

Noise (high-pitched squeal when the brakes are applied).............

60

Brake roughness or chatter (pedal pulsates) .........:ccsccesceeeseeeeeeess

61

22 ~~ Excessive pedal effort required to stop Vehicle ...........-sseesseeesnees

62

Excessive brake pedalitraVelieemnsecsscestresttecunt pret a renee sner

63

PAGING DVAKCS eeivcheats cotta ws ceciessccedastecees seeche sects cnouhaey erie arene

64

Grabbing or uneven braking ACtiON....c..ccccsctssersscssesneeescsesesseesses

65

24

Brake pedal feels spongy when depressed ..........::seseseseieneiee

66

CONSCI RN ENC oe ee OE NE E ere Se ELIA COANE NOAIAOG hive ccna csiswesvacodsonionsentsensandeesessernnarusrseaeite

25 26

Brake pedal travels to the floor with little resistance ..............0000 ostcegreseereatyaie Parking brake does NOt MOI ssa crcxssas sareeseeteepkeetaee

67 68

HALEN OIA ICAKAGC soap ees cs chen sercsn ears. acsizeessvcoonasercerocscaasenneneans (SOOM IOSS caer saat sass codec cabin ce wt, waters sasuke sur ee anes spatssareusrioes

PHY 28

F : Suspension and steering systems

cole teacroes feetnee sete iter, ctn POOMEOR AINGIRCUIATION e teras ceteceee

29

ensueasserts xeazeae dase eeeaees Vehicle pulls to ONG: SIGE... Siccseceenexeseasearcescen

69

Abnormallion excessive tife Wats ...cc.nm cc -crnecsccevexsssecneenste vacate sts

70

Wheelsmakesial thumpingimolSe\reseccstarscccc cereesaec stene nn ane

71

23

i

Cooling system

COD oUtTLS LI pe ol A

ols Oe eT Senet

Clutch Pedal travels to floor - no pressure or very little resistance........... Fluid in area of master cylinder dust cover and on pedal.............. cinveraneusactn sens eaosedes FIUNGNOMMOICASE CYVIIMGCts ete cecretes cree tee rassvanduss Pedal feels spongy When Cepressed ........:cccceeeceseeeesesteeteeteeteees Unableto SeleCt Gears t

io

tat

%

ay

BRN oa

Me

REAR

|

RELAY

ae

DK GRNwe

|

WIPER

——

ee see

BLK/

| | | ani

S

BRN/ WHT

LT BLU

B

GEAR Wasver

MOTOR

ras |

oS

|

jMODULE (GEM)

es

DK GRN

WHT/ ORG

= 7 GENERIC |ELECTRONIC 4

PNK/ BLK

BLK/ LT BLU

BRN WHT

(OR LT BLU)

(OR BRN) REAR WIPER MOTOR ASSEMBLY

r |

==

INT

WIPER N

1WIPER/ |WASHER |SWITCH

orF |

| | | | ee

BLK

BLK

BLK

BLK

BLK

q)

a

le

Rear wiper/washer system

Chapter 12 HOT IN RUN OR START treet ware

CENTRAL TUNC TION BOX

(CJB) |

HOT IN RUN OR START oe yee |

oe

|

|

nes

|

FUSE

PCM

4

|

es

HOT AT ALL TIMES

a =

FUSE 26

na FUSE 25

40A

HOT AT ALL TIMES Sie

“TBATTERY JUNCTION |BOX (BJB)

FUSE 17

40A

15A

| Aas

|

vu

WHT/ vio res

|

“a

|POWER DIODE

|

LE

Fe |

|

a9

|

12-27

Chassis electrical system

BLK/ LT GRN

ESE

Copan | eee

4

BLK/ LT GRN

PNK/ LT BLU (OR PNK/ BLK)

peel

es

BLK/ LT GRN

BLK LT BLU

, 30

casey

|

WHT/VIO

a

A |

‘

| Al |

x @

| |

|

DK BLU

|

a;

| |

:

BLK/LT_GRN

BLK/ LT GRN

i BE

BLK/ LT GRN

Kn

RED/ORG |

|

HIGH SPEED FAN

'

CONTROL RELAY 1

BLOWER

WHT/VIO DK BLU/GRY

|

Fite |

ER

-

oh

T BLU/BLK

BLK/LT_GRN

MOTOR

RELAY

TAN/YEL

tie FRONT

MEDIUM SPEED FAN CONTROL RELAY

BLOWER MOTOR

WHT/VIO LT_BLU TBLK/LT_GRN

es

BLK/LT

GRY/RED

lil

BLU

DK_GRN/ORG BLK/YEL

LOW SPEED FAN CONTROL RELAY WHT/VIO | | I | | | | | |

| |_|

|PNK/YEL | ea

IPNK/LT BLU (OR PNK/BLK) |GRY/WHT

?

GRY

A/C CLUTCH

RELAY

/WHT

|

J A/C

COMPRESSOR

|GRY/WHT

BLK/ ORG

|

Pe BLK di

4

| |

i. gee

RED/ ORG e

| OS ee ee ee BATTERY JUNCTION BOX (BJB

HIGH SPEED RLY CTRL 1 CYL TEMP SENSOR INPUT DUAL PRESSURE SW SIG MED SPEED RLY CTRL LOW SPEED RLY CTRL | A/C CLUTCH RLY CTRL| | DUAL PRESSURE SW SiG!

SIGNAL RETURN|

GRY/} RED} DK

RED/ ORG

RED/ ORG

LT BLU/ BLK

BLU

LT GRN/RED DK GRN/ORG DK BLU/GRY LT BLU PNK/YEL BLK/YEL ORG ORG

POWERTRAIN CONTROL MODULE (PCM)

(OR BLK)

BLK

ENGINE COOLING FAN MOTOR 2

ENGINE COOLING FAN MOTOR 1

A/c CLUTCH SOLENOID

|| |

|

BLK

e

CYLINDER HEAD TEMPERATURE SENSOR

ORG

BLK/ ORG (OR

BLK)

Z

LT_GRN/RED

2

Air conditioning system - four-cylinder models (1 of 2)

12

12-28

Chapter 12

Chassis electrical system

ee

BLK/LT BLU

|,

— gerne cil4 MAX | DEFROST

NORMAL

|

VENT FLOOR/

| |

OFF |VENT

IMODE

|SWITCH |

BRN/YEL__/

r

|

| DEFROST.

Max

EJ

MIX « FLOOR opp |FLOOR/VENT vio

Vio (OR _DK_GRN/YEL

é

;

ORG/BLK

LT GRN/WHT

SSS

MEDIUM 2 Se MEDIUM 1

HIGH

BLOWER MOTOR SWITCH

LOW

YEL/RED 1 ORG/BLK 9 BRN/YEL » 5 BLK/LT BLU

uy

ile

aLK : LT_BLU/RED

|.

4 DK_GRN/ORG 5 BLK/YEL

i. ©)

A/C CLUTCH CYCLING PRESSURE WITCH SWITC

BLK

vio

yeh

i: ILLUMINATION

esl FUNCTION SELECTOR

SWITCH ASSEMBLY

e

RED/YEL

BLK. INTERIOR LT BLU/RED ~ LIGHTS SYSTEM DUAL PRESSURE SWITCH

ORG/BLK RED/YEL

1

LT_GRN/WHT

e 2 DK GRN/ORG

A

1

YEL/RED

$12:

BLK/ORG (ih pete

ie

BLK

1: NORMAL PRESSURE 2: HIGH PRESSURE

=

BLK FRONT BLOWER MOTOR RESISTOR ASSEMBLY

Air conditioning system - four-cylinder models (2 of 2)

.

Chapter 12 HOT IN RUN OR START

een a Se

+ FUSE an

*

CENTRAL

JUNCTION 80x (CJB) |

PM

|

|

-

FUSE

a

FUSE

26

50A

BLK/ LT GRN|

ai

23

50A

|

40A

ef BLK/ LT GRN

|

BLK/ LT GRN

WHT/

-—-

Pee

vio

WHT/VIO

|

FUSE

25

IL |

[BsSacer

ie

OT MES

le

|

|

|piove

|

12-29

Chassis electrical system

|

iM

|

WHT/VIO.

|

| LT BLU

—*

||

PNK/YEL

|

|

VIO/PNK

HIGH SPEED FAN

CONTROL

RELAY

|

GRY/WHT GRY/WHT

(OR BLK

BLK/LT GR N

|

|

GRY/RED

ARES

A/C CLUTCH RELAY

GRY/WHT il

1

|

|

A/C COMPRESSOR

CLUTCH

aos ey LK (OR BLK L Bee

DIODE

pe

al

BATTERY JUNCTION BOX (BJB)

LT BLU

ns

WHT/VIO

| — | tye Ss

LT BLU/BLK

Ss

Og seo HIGH SPEED FAN

WHT/VIO 1 LT_BLU/BLK_ ViO/PNK_(OR BLK) 5

BLK/ a8

cea

(OR Oke

aa

‘;

eee |_|(ae

DK _BLU/YEL

eee eee) ak oe es nee Riese

CONTROL RELAY 2

BRN VED > 7 ORG/BLK

il

WHT/VIO

+ =

LT BLU/BLK

Boe A

4

:

aa ;°

fig Seay

!

|

a

PST

LOW SPEED FAN CONTROL RELAY

RED/ORG

OK BLU |

ENGINE COOLING FAN MOTOR 2

if

BLK/LT_GRN

| RED/ORG

pe eel eee

|

BATTERY JUNCTION BOX (BJB)

ic

TAN/YEL

(|, J FRONT BLOWER MOTOR

GRY/

LOW SPEED RLY CTRL

ORG/BLK

@

pane: ENGINE COOLANT SENS (INPUT INP DUAL PRESSURE SW SIG | MED SPEED RLY CTRL | HIGH SPEED RLY CTRL 1| A/C CLUTCH RLY CTRL | DUAL PRESSURE SW SIG! SIGNAL ey

(OR BLK),

sure DK_GRN/ORG

+

BLU

caAED RY |}-——

oRY/

RED

a

TAN/YEL 4

LT BLU

POWERTRAIN CONTROL

MODULE (PCM)

Pica

ENGINE

== }——--l— ae

COOING FAN MOTOR 1

Peay)

NG

: BLK

SS

Ui

a/c CLUTCH SOLENOID

os

V

|. pA

ae ee

|

BLOWER MOTOR RELAY BLK

ENGINE COOLANT

TEMPERATURE (ECT) SENSOR

ORG

LT_GRN/RED

e

BLK/ ORG (OR BLK)

e

BLK/ ons OR BLK) o.

Air conditioning system - V6 models (1 of 2)

e

BLK/ ne OR BLK)

12

Chapter 12 Chassis electrical system

12-30

HOT IN RUN » OR START aes la eae oI GENTRALSUUN | jBOX (CJB) |

|

|

th

|

2

| ER

FUSE

25

BLK LT BLU LT BLU/RED

ah

See

DK_BLU/YEL

INTERIOR LIGHTS

(OR BLK

(€)

SYSTEM

|

BLK

|

|e

w

ILLUMINATION

|

LT_BLU/BLK BLK

BLK/LT

BLU

Ty MAX DEFROST,

) VIO/PNK (OR BLK)

NORMAL VENT

MIX

MODE

FLOOR/

SWITCH

VENT WHT/VIO

BRN/YEL

MEDIUM SPEED FAN CONTROL RELAY

VIO

1 WHT/VIO 2 LT_BLU/BLK 3 MIOZPNK (OR BLK 4 DK BLU/YEL_(OR_BLK

) VIO_(OR_DK_GRN/YEL)

(

ORG/BLK

LT GRN/WHT

eee DK GRN/ORG S7 -BRNZYEL 8 ORG/BLK

MEDIUM 2 ree ae MEDIUM 1

Bee

BB is BLK

,

HIGH

BLOWER MOTOR SWITCH

LOW

YEL/RED

aE

VIO/PNK

FUNCTION SELECTOR SWITCH ASSEMBLY

(OR BLK

ENGINE COOLING FAN RESISTOR

A/C CLUTCH CYCLING PRESSURE SWITCH

vio ; e

RED/YEL LT_GRN/WHT

RED/YEL

t

e

a

DK GRN/ORG

BLK/YEL BLK/

‘lp

ORG

1

eo

BLK /ORG EK ORS

.

(OR

BLK)

BLK

A

BLK

( [Select

g,

1: NORMAL PRESSURE 2: HIGH PRESSURE DUAL

PRESSURE

eae

FRONT BLOWER MOTOR RESISTOR ASSEMBLY

SWITCH

*

Air conditioning system - V6 models (2 of 2) /

be

Chapter 12

HOT IN START OR- RUN

fare

HOT AT ALL TIMES

niles

HOT IN START OR RUN

Se

Sasa

FUSE

Tass

Sit = ee

HOT

CENTRAL

FUSE 16

24

FUSE

5

Box (8)

|

10A

15A

5A

|

bes

pie cs Se fear RED/

LT GRN/

YEL

ruger

LT BLU/]}

RED

PNK

pe

LT BLU/

eas TAN/

PNK)

LT GRN/

YEL

|

acc®

e°

TAN/

LT BLU]

|

Run TAN/

LT BLU

(OR LT BLU/YEL)

Bee

START|

CR cy Me

LT BLU

(2.0L)

LT GRN

RED

If

Work

|

@

RED/

|

|

Beet

AT ALL TIMES

[~~ — FIGNITION

|

|

12-31

Chassis electrical system

ad

:

--

ORC

|

ORG

|

INSTRUMENT[~ — — — — 7 4

CLUSTER)

|

SPEED | CONTROL INDICATOR

abe te eludes

BRAKE

|

st

DEACT—

PEDAL POSITION SWITCH

IVATOR SWITCH

CLUTCH

LT BLU/ YEL

|

T tt crnl | e

|

Bee

LT BLU/YEL__

e

ORG/

LT BLU/

LT BLU

YEL

A/T

ORG/LT BLU

M/T

aay

GRY/BLK . souND

LT BLU/YEL

GRY/BLK

|

SWITCH :

umireo—+|

BPs

Reeraneees

SS

, SYSTEMS

H

DK GRN/ORG LT_BLU/PNK RED/LT_GRN BLK ee

WHT/LT BLU

ee

BS PE

ee

ee

|

| ||

|

i

i it

\

|

GRY/BLK___

LT _GRN LT BLU/BLK

|

BLK (OR BLK/ORG) q:

W/

ABS

|

CONTROL SERVO

POWERTRAIN CONTROL PCM

TURBINE SHAFT

SPEED SENSOR

LT BLU/ PNK

A/T

MODULE '(PCM)

DK BLU/ YEL

ABS TEST CONNECTOR

BRN/| LT GRN

LT BLU/ PNK

LT BLU/ BLK

DK BLU/ YEL

DK BLU/ YEL

OUTPUT

DK GRN/ ORG

AIR BAG|

aii

SLIDING |

SHAFT SPEED

VEHICLE SPEED

SENSOR

SENSOR

{

a

ct

CONTACT

a

i

!

Be scy ae

z

——

Noa ial

| |

NCA

=s

x

en

sl f

z/{t °

|

fe)

aia

=

|+

z

=|

!

°

|

4

wee

fay




fe Weal (et

WHEEL/SPEED

BRN/

LT GRN

i aS

(as ne aa bey

| |

/

&

2 | z2

6/95 oO [s)

CONTROL

ae iy

a

.

° BLK S

SWITCH

42 Cruise control system

12-32

Chapter 12 Chassis electrical system HOT W/ IGNITION RELAY ENERGIZED

—-HOT_ AT _ALL TIMES

HOT AT ALL TIMES

HOT AT hne ALUETIMES 7 da

CENTRAL J

x.

Meco

|

Artes

JUNCTION

BOX

|

154 FUSE 6 10A

FUSE 20 15A

FUSE 24 15A

|

FUSE at 10A

| an

? [Sane

|

See

ORG/| YEL| )

|

ORG/YEL

ORG/| YEL]

fee

[

BLK/] RED/| LT) LT PNK] WHT] GRN/}GRN/|

‘-

WHT

L

ate ye)

LT] GRN/}

WHT

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IND-1

Index A | About this manual, 0-5 _ Accelerator cable, removal and installation, 4-10 _ Accumulator, air conditioning, removal and installation, 3-13

- Acknowledgements, 0-2 Air conditioning accumulator, removal and installation, 3-13 and heating system, check and maintenance, 3-10 compressor, removal and installation, 3-12

condenser, removal and installation, 3-14 orifice tube, removal and installation, 3-15 pressure cycling switch, replacement, 3-14 - Air filter housing, removal and installation, 4-8 _ Air filter, check and replacement, 1-18 _ Airbag system, general information and precautions, 12-23

Alternator, removal and installation, 5-8 Antenna and cable, removal and installation, 12-14 Antifreeze, general information, 3-2 Anti-lock Brake System (ABS), general information, 9-2 Automatic transaxle, 7B-1 through 7B-6 auxiliary cooler, removal and installation, 7B-4

diagnosis, general, 7B-1 fluid change, 1-22 level check, 1-10 mount, replacement, 7A-4 overhaul, general information, 7B-6 removal and installation, 7B-4 shift cable, replacement and adjustment, 7B-3 lever, replacement, 7B-2 ‘Automotive chemicals and lubricants, 0-18

B Battery cables, replacement, 5-4 check, maintenance and charging, 1-13 check, removal and installation, 5-2 emergency jump starting, 0-14 jump starting, 0-14 Blower motor resistor and blower motor, replacement, 3-9 Body repair major damage, 11-3 minor damage, 11-2 Body, 11-1 through 11-28 Body, maintenance, 11-1 Booster battery (jump) starting, 0-14 Brakes, 9-1 through 9-14 Anti-lock Brake System (ABS), general information, 9-2 caliper, removal and installation, 9-4 check, 1-16 disc, inspection, removal and installation, 9-5 fluid change, 1-21 level check, 1-8 hoses and lines, inspection and replacement, 9-11 hydraulic system, bleeding, 9-11 light switch, replacement, 9-13 master cylinder, removal and installation, 9-10 pads, disc brake, replacement, 9-2 parking brake, adjustment, 9-12 power brake booster, check, removal and installation, 9-12 shoes, drum brake, replacement, 9-6 wheel cylinder, removal and installation, 9-8 Bulb replacement, 12-19

IND

IND-2

Index

Bumpers, removal and installation, 11-7 Buying parts, 0-6

C Cable replacement accelerator, 4-10 antenna, 12-14 battery, 5-4

hood release, 11-6 Caliper, disc brake, removal and installation, 9-4 Camshaft oil seals, four-cylinder engine, replacement, 2A-10 Camshaft Position (CMP) sensor, replacement, 6-9 Camshafts and cam followers (four-cylinder engine), removal, inspection and installation, 2A-11 Camshafts, hydraulic lash adjusters and rocker arms, removal inspection, and installation (V6 engine), 2B-12 Catalytic converters, 6-19 Center console, removal and installation, 11-22 Charging system alternator, removal and installation, 5-8 check, 5-7 general information and precautions, 5-7 Chassis electrical system, 12-1 through 12-24 Chemicals and lubricants, automotive, 0-18 Circuit breakers, general information, 12-4 Clutch components, removal, inspection and installation, 8-2 description and check, 8-2 fluid level check, 1-8

hydraulic system, bleeding, 8-2 master cylinder, removal and installation; 8-2 release bearing and lever, removal, inspection and installation, 8-4 release cylinder, removal and installation, 8-2 Clutch and driveline, 8-1 through 8-12 Clutch Pedal Position (CPP) switch, replacement, 6-10

Coil spring (rear), removal and installation, 10-8 Coils, ignition, replacement, 5-6 Compressor, air conditioning, removal and installation, 3-12 Condenser, air conditioning, removal and installation, 3-14 Control arm (front), removal, inspection and installation, 10-6 Conversion factors, 0-16

Coolant expansion tank, removal and installation, 3-6 temperature sending unit, check and replacement, 3-8 level check, 1-8

Cooling system check, 1-14 fans, check and replacement, 3- 4 general information, 3-2 servicing (draining, flushing and refilling), 1-20 Cooling, heating and air conditioning systems, 3-1 through 3-16 Cowl cover and vent tray, removal and installation, 11-11 Crankshaft front oil seal, replacement four-cylinder engine, 2A-10 V6 engine, 2B-7 Crankshaft Position (CKP) sensor, replacement, 6-10 Crankshaft pulley, removal and installation four-cylinder engine, 2A-6 V6 engine, 2B-7 Crankshaft, removal and installation, 2C-14 Cruise control system, description, 12-22 Cylinder compression check, 2C-4 Cylinder Head Temperature (CHT) sensor, replacement, 6-11 Cylinder head, removal and installation four-cylinder engine, 2A-14 V6 engine, 2B-15

D Dashboard trim panels, 11-23 Daytime Running Lights (DRL), general information, 12-23 Defogger, rear window, check and repair, 12-15 Diagnosis, 0-19 Differential, rear (4WD models) lubricant change, 1-23 removal and installation, 8-11 Disc brake caliper, removal and installation, 9-4 disc, inspection, removal and installation, 9-5 pads, replacement, 9-2 Door latch, lock cylinder and handles, removal and installation, 11-14 removal, installation and adjustment, 11-14 trim panels, removal and installation, 11-12 window glass regulator, removal and installation, 11-19 window glass, removal and installation, 11-17 Driveaxle boot check, 1-19 replacement, 8-6 oil seats, replacement front, 7A-2 rear (4WD models), 8-11 removal and installation, 8-4

IND-3

Index SSeS

SSS

SS

Drivebelt check and replacement, 1-21 tensioner replacement, 1-21 _ Driveplate (V6 engine), removal and installation, 2B-18 Driveshaft (4WD models), removal and installation, 8-10 Drum brake shoes, replacement, 9-6

E Electric side view mirrors, description, 12-22 Electrical troubleshooting, general information, 12-1 Emissions and engine control systems, 6-1 through 6-28 Engine

Four-cylinder engine, 2A-1 through 2A-22 camshaft oil seals, replacement, 2A-10 camshafts and cam followers, removal, inspection

and installation, 2A-11 crankshaft front oil seal, replacement, 2A-10 crankshaft pulley, removal and installation, 2A-6 cylinder head, removal and installation, 2A-14 engine mounts, check and replacement, 2A-21 exhaust manifold, removal and installation, 2A-6 flywheel, removal, inspection and installation, 2A-20 intake manifold, removal and installation, 2A-6 oil pan, removal and installation, 2A-17 oil pump, removal, inspection and installation, 2A-17 rear main oil seal, replacement, 2A-21 repair operations possible with the engine in the vehicle, 2A-2 timing belt, removal, inspection and installation, 2A-7 Top Dead Center (TDC) for Number 1 piston, locating, 2A-3 valve clearances, checking and adjustment, 2A-5 valve cover, removal and installation, 2A-4 _ General engine overhaul procedures, 2C-1 through 2C-18 crankshaft, removal and installation, 2C-14 cylinder compression check, 2C-4 engine overhaul

disassembly sequence, 2C-8 reassembly sequence, 2C-18 engine rebuilding alternatives, 2C-5 engine removal, methods and precautions, 2C-5 engine, removal and installation, 2C-6 initial start-up and break-in after overhaul, 2C-18 oil pressure check, 2C-3

SSS

SS

pistons and connecting rods, removal and installation, 2C-8 vacuum gauge diagnostic checks, 2C-4 V6 engine, 2B-1 through 2B-18 camshafts, hydraulic lash adjusters and rocker arms, removal inspection, and installation, 2B-12

crankshaft pulley and front oil seal, removal and installation, 2B-7 cylinder head, removal and installation, 2B-15 driveplate, removal and installation, 2B-18 engine front cover, removal and installation, 2B-8 engine mounts, inspection and replacement, 2B-18 exhaust manifold; removal and installation, 2B-6 intake manifold, removal and installation, 2B-5 oil pan, removal and installation, 2B-16 oil pump, removal, inspection and installation, 2B-17 rear main oil seal, replacement, 2B-18 repair operations possible with the engine in the vehicle, 2B-2 timing chains, tensioners, and chain guides, removal, inspection, and installation, 2B-9 Top Dead Center (TDC) for number one piston, locating, 2B-3 valve cover, removal and installation, 2B-3

Engine Coolant Temperature (ECT) sensor, replacement, 6-11 Engine cooling fans, check and replacement, 3-4 Engine electrical systems, 5-1 through 5-12 general information, precautions and battery disconnection, 5-2 Engine mounts, check and replacement four-cylinder engine, 2A-21 V6 engine, 2B-18 : Engine oil and filter change, 1-11 Engine overhaul disassembly sequence, 2C-8 general information, 2C-2 reassembly sequence, 2C-18 rebuilding alternatives, 2C-5 removal, methods and precautions, 2C-5 Engine, removal and installation, 2C-6 Evaporative emissions control (EVAP) system, general information and component replacement, 6-20 Exhaust Gas Recirculation (EGR) system, general information and component replacement, 6-23 Exhaust manifold, removal and installation four-cylinder engine, 2A-6 V6 engine, 2B-6 Exhaust system check, 1-19 inspection and component replacement, 4-17 Expansion tank, removal and installation, 3-6

IND

IND-4

= Fans, engine cooling, check and replacement, 3-4 Fault finding, 0-19 Filter replacement engine air, 1-18

engine oil, 1-11 , fuel, 1-19 Fluid level checks, 1-7 automatic transaxle fluid, 1-10 brake and clutch fluid, 1-8

Index

pump/level sending unit module, removal and installation, 4-6 rail and injectors, removal and installation, 4-15 system check, 1-17

tank cleaning and repair, general information, 4-8 removal and installation, 4-7 throttle body, inspection, removal and installation, 4-13 Fuel and exhaust systems, 4-1 through 4-20 Fuses and fusible links, general information, 12-3

engine coolant, 1-8 engine oil, 1-7

manual transaxle, 1-18 power steering fluid, 1-9 transfer case, 1-18 windshield washer fluid, 1-9 Fluids and lubricants capacities, 1-2 recommended, 1-1 Flywheel (four-cylinder engine), removal, inspection and installation, 2A-20 Four-cylinder engine, 2A-1 through 2A-22 camshaft oil seals, replacement, 2A-10

camshafts and cam followers, removal, inspection and installation, 2A-11 crankshaft front oil seal, replacement, 2A-10

crankshaft pulley, removal and installation, 2A-6 cylinder head, removal and installation, 2A-14

engine mounts, check and replacement, 2A-21 exhaust manifold, removal and installation, 2A-6 flywheel, removal, inspection and installation, 2A-20 intake manifold, removal and installation, 2A-6 oil pan, removal and installation, 2A-17 oil pump, removal, inspection and installation, 2A-17 rear main oil seal, replacement, 2A-21 repair operations possible with the engine in the vehicle, 2A-2 timing belt, removal, inspection and installation, 2A-7

Top Dead Center (TDC) for Number 1 piston, locating, 2A-3

valve clearances, checking and adjustment, 2A-5 valve cover, removal and installation, 2A-4 Fraction/decimal/millimeter equivalents, 0-15 Front fender, removal and installation, 11-10 Fuel

filter replacement, 1-19 general information and precautions, 4-2 injection system, general check, 4-12 lines and fittings, general information, 4-4 Multiport Fuel Injection (MFI) system, general information, 4-11 pressure relief procedure, 4-2 pulsation damper, removal and installation, 4-14 pump/fuel pressure, check, 4-2

G General engine overhaul procedures, 2C-1 through 2C-18

crankshaft, removal and installation, 2C-14 cylinder compression check, 2C-4 engine overhaul disassembly sequence, 2C-8 reassembly sequence, 2C-18 engine rebuilding alternatives, 2C-5 engine removal, methods and precautions, 2C-5 engine, removal and installation, 2C-6

initial start-up and break-in after overhaul, 2C-18 oil pressure check, 2C-3 pistons and connecting rods, removal and

installation, 2C-8 vacuum gauge diagnostic checks, 2C-4 Grille, radiator, removal and installation, 11-11

H Hazard flasher and turn signal, check and replacement, 12-5 Headlight adjustment, 12-17

bulb, replacement, 12-16 housing, replacement, 12-18 Heater core, replacement, 3-10 Heater/air conditioner control assembly, removal and installation, 3-9 Hinges and locks, maintenance, 11-3 Hood latch and release cable, removal and installation, 11-6 Hood, removal, installation and adjustment, 11-3 Horn, replacement, 12-18 Hoses, underhood, check and replacement, 1-15 How to use this manual, 0-5 Hub and bearing assembly, removal and installation front, 10-7 rear, 10-9

|

IND-5

Index

Identification numbers, 0-6 _ Idle Air Control (IAC) vaive, replacement, 6-19

_ Ignition system check, 5-5

lubricant change, 1-23 level check, 1-18 mount, replacement, 7A-4 overhaul, general information, 7A-4

_ removal and installation, 7A-2

coil check (V6 engines), 1-25 coils, replacement, 5-6 general information, 5-5 - switch and key lock cylinder, replacement, 12-5 Initial start-up and break-in after overhaul, 2C-18 Instrument cluster, removal and installation, 12-10 panel switches, replacement, 12-8 panel, removal and installation, 11-25 intake manifold, removal and installation four-cylinder engine, 2A-6

V6 engine, 2B-5

.

Introduction to the Ford Escape and Mazda Tribute, 0-5

shift cables (4WD models), removal and installation, 7A-2 lever, removal and installation, 7A-2 linkage (2WD models), removal and installation, 7A-2 Mass Air Flow (MAF) sensor, replacement, 6-12 Master cylinder, removal and installation brake, 9-10 clutch, 8-2 Mirrors, removal and installation, 11-20 Mode select switch, transfer case, replacement, 7C-2 Multiport Fuel Injection (MFI) system, general information, 4-11

e a

Jacking and towing, 0-13

- Jump starting your vehicle, 0-14

Key lock cylinder and ignition switch, replacement, 12-5 Knock sensor, replacement, 6-12

O Oil cooler, removal and installation, 3-15 Oil pan, removal and installation

four-cylinder engine, 2A-17 V6 engine, 2B-16 Oil pressure check, 2C-3 : Oil pump, removal, inspection and installation four-cylinder engine, 2A-17 V6 engine, 2B-17 Oil, engine

‘ change, 1-11 level check, 1-7

Ara

Liftgate latch remote control, latch and window latch, removal and installation, 11-21 removal, installation and adjustment, 11-20

_ Lubricants and fluids capacities, 1-2 recommended,

On-Board Diagnostic (OBD) system and Diagnostic Trouble Codes (DTCs), 6-3 Orifice tube, air conditioning, removal and installation, 3-15 Output Shaft Speed (OSS) sensor, replacement, 6-12 Owners manual and VECI label information, 1-7 Oxygen sensors, general information and replacement, 6-13 .

1-1

Mi ' Maintenance schedule, 1-6 Maintenance techniques, tools and working facilities, 0-7

Manual transaxle, 7A-1 through 7A-4

driveaxle oil seals, replacement, 7A-2

P Pads, disc brake, replacement, 9-2 Parking brake, adjustment, 9-12 Parts, replacement, buying, 0-6 Pistons and connecting rods, removal and installation, 2C-8

IND

- IND-6 ee

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index SS

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ST

Positive Crankcase Ventilation (PCV) system, general information and component replacement, 6-26 Positive Crankcase Ventilation (PCV) valve replacement (four-cylinder models), 1-24 Power brake booster, check, removal and installation, 9-12 Power door lock system, description, 12-22 Power steering

| |

| |

|

fluid cooler, removal and installation, 10-15

|

fluid level check, 1-9 Power Steering Pressure (PSP) switch, replacement, 6-16 pump, removal and installation, 10-13 steering gear, removal and installation, 10-12 system, bleeding, 10-15 Power window system, description, 12-22 Powertrain Control Module (PCM), replacement, 6-17 Pressure cycling switch, air conditioning, replacement, 3-14

P